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Although I have postponed the fitting of a power steering column to my Cabrio, until after I get it through the IVA test - it would be just another item they could find an issue with - I thought I'd share how I have prepared it ready for installation. Its not for everyone, as it requires some minor, but significant welding, and the use of a lathe. However, all the preparatory work in the enclosed photos can be carried out by anyone: and the difficult bits of welding the Sierra column sections in a lathe can be taken to any decent machine shop, and will not cost the earth. Thanks go to Lee Hunter for identifying that this modification actually works and blazing the trail.
A standard Sierra Adjustable Column + Inner Shaft.
Corsa C EPAS Fixed Steering Column.
This is an Electric power steering column from a Corsa C - it comes with the ECU attached to the column, and is known as EPAS (Electric Power Assisted Steering).
A special torxx socket is required to undo the centre bolt.
The EPAS assembly can be dismantled to this stage by pulling apart friction fit connections - it does require some effort, but there is only friction holding it.
Removing the inner shaft from the upper column assembly is more difficult. I used an angle grinder to carefully cut away the outer case - it is then discarded.
The Corsa has a lower link with two u/js, which is splined to the output shaft of the EPAS column. I simply cut the splined section off the u/j with the trusty angle grinder. A 1mm thin slitting blade makes this very easy.
I want to retain the Sierra columns reach adjustment, so have shortened the Sierra's lower outer shaft, and welded the two triangular sections closer to each other, and then fitted a shortened inner triangular section. This provides 50mm of reach adjustment with the white nylon bush sliding in either one or both of the outer triangular sections. A spin off is that this column is truly collapsable.
Note: This is the only variation from the pioneering system fitted by Lee Hunter. Lee chose to weld the Sierra's inner triangular shaft direct to the splined boss, making the overall steering column assembly fixed. Given that probably most drivers want the steering wheel pushed away from them in a Cabrio, reach adjustment may not be a big issue, so it is probably a good compromise - ( and, it will simplify installation too).
As the Forum will prevent me from adding more Photos to this posting - I'll continue with the upper assembly in Part 2 !
A standard Sierra Adjustable Column + Inner Shaft.
Corsa C EPAS Fixed Steering Column.
This is an Electric power steering column from a Corsa C - it comes with the ECU attached to the column, and is known as EPAS (Electric Power Assisted Steering).
A special torxx socket is required to undo the centre bolt.
The EPAS assembly can be dismantled to this stage by pulling apart friction fit connections - it does require some effort, but there is only friction holding it.
Removing the inner shaft from the upper column assembly is more difficult. I used an angle grinder to carefully cut away the outer case - it is then discarded.
The Corsa has a lower link with two u/js, which is splined to the output shaft of the EPAS column. I simply cut the splined section off the u/j with the trusty angle grinder. A 1mm thin slitting blade makes this very easy.
I want to retain the Sierra columns reach adjustment, so have shortened the Sierra's lower outer shaft, and welded the two triangular sections closer to each other, and then fitted a shortened inner triangular section. This provides 50mm of reach adjustment with the white nylon bush sliding in either one or both of the outer triangular sections. A spin off is that this column is truly collapsable.
Note: This is the only variation from the pioneering system fitted by Lee Hunter. Lee chose to weld the Sierra's inner triangular shaft direct to the splined boss, making the overall steering column assembly fixed. Given that probably most drivers want the steering wheel pushed away from them in a Cabrio, reach adjustment may not be a big issue, so it is probably a good compromise - ( and, it will simplify installation too).
As the Forum will prevent me from adding more Photos to this posting - I'll continue with the upper assembly in Part 2 !
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