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Fabricating a steering column
andyd - 4/1/07 at 04:30 PM

I'm thinking of doing this due to wanting a new registration (so I can have a private plate eventually) and the requirement being only one part reconned (which will be the Hayabusa engine).

I know that it has to be collapsible and remembering what the Sierra column does, do I just need the telescoping ability i.e. where the triangular section slides on a plastic bearing up into the main shaft or would I need to fabricate something else to make it not only SVA friendly but head/face/body friendly in the event of a front impact?


oliwb - 4/1/07 at 04:32 PM

Correct me if I'm wrong but can't you have something like two or more joints with more than 15 degrees deflection in order to comply with the collapsible-ness?? Oli.


scottc - 4/1/07 at 04:32 PM

Would it be easier to put 2 Universal Joints in it instead?


andyd - 4/1/07 at 04:35 PM

Ooo... I'll have to get the SVA book out and see what it says!

If I can just have a deflection that would make things soooo much easier.


Agriv8 - 4/1/07 at 05:21 PM

I am running the high angle joints from rally design to go across the top of the v8 manifolds ( could have gone under apart from the implication of tangling with my size 13 feet !!!).

the high angle joint runs at about 30 to 35 deg ( est ) to the rack.

The issue with running multiple joits is you sill likley have to support the bar running between each joint.

Ahh just found a photo might show what I mean better

steering UJ
steering UJ


regards

Agriv8


Marcus - 4/1/07 at 05:27 PM

Yes, you're ok with an angled column, but don't forget you still need a collapsible steering wheel boss.


andyd - 4/1/07 at 07:32 PM

quote:
Originally posted by chris mason
rather than fabricate one, wouldn't it be easier to just buy a new one (sierra or whatever you need)

That does depend on how much a new one would be which I must confess to not finding out.

I have access to CNC machines and a lathe so I'm betting that making my own would be cheaper than Mr Ford or Mr Vauxhall etc.

Besides, where's the fun in buying someone else's when you can make your own?


muzchap - 4/1/07 at 08:22 PM

Not being funny - but I used a second hand steering column and still got an 06 plate.

They don't check that - all they want to see is receipts for the chassis (new), receipts for the engine and refurbishment and proof of age, as well as any other receipts you have.

Don't forgot the only restrictions are on 'major' items like engine/gearbox/diff. If you can provide receipts for these as new you can use a second hand column.

Fair play you have access to a lathe etc - but trust me, you'll find plenty more uses for it than a steering column


907 - 4/1/07 at 09:59 PM

quote:
Originally posted by andyd
quote:
Originally posted by chris mason
rather than fabricate one, wouldn't it be easier to just buy a new one (sierra or whatever you need)

That does depend on how much a new one would be which I must confess to not finding out.

I have access to CNC machines and a lathe so I'm betting that making my own would be cheaper than Mr Ford or Mr Vauxhall etc.

Besides, where's the fun in buying someone else's when you can make your own?



I just love that last sentence.


I used two bits of pipe that would slide inside each other and milled a slot in both.

A pic explains it better than I can.


I should point out though that it hasn't passed SVA yet. Hopefully it will.



Paul G


Can I point out (I've had a U2U) that the milled slot is only in one side of each pipe.
Inside the smallest pipe is a short length of solid bar with a M8 thread tapped into it.
An M8 stud is screwed into this which protrudes through the slots and then has the nut (nyloc) screwed on.
This arrangment clamps the walls of the pipes together.

IT IS NOT A BOLT RIGHT THROUGH.

[Edited on 5/1/07 by 907] Rescued attachment column-s.jpg
Rescued attachment column-s.jpg


andyd - 4/1/07 at 11:11 PM

Muzchap - thanks for the info on what will get me a current plate. I'd just assumed that they'd want to see receipts for everything purchased including raw materials if fabricated i.e. the chassis steel. I may consider revising my plans on this depending on the rest of the build.

Paul - You're a star, that's exactly what I had in mind - a tube inside a tube with some form of friction between them. Have you sorted the "collapsible boss" issue though?


907 - 5/1/07 at 12:43 AM

quote:
Originally posted by andyd
Muzchap - thanks for the info on what will get me a current plate. I'd just assumed that they'd want to see receipts for everything purchased including raw materials if fabricated i.e. the chassis steel. I may consider revising my plans on this depending on the rest of the build.

Paul - You're a star, that's exactly what I had in mind - a tube inside a tube with some form of friction between them. Have you sorted the "collapsible boss" issue though?





I think so.

The top bit is a Nova column and has this bit of chicken wire in it.

Paul G Rescued attachment chicken-wire.jpg
Rescued attachment chicken-wire.jpg


3GEComponents - 5/1/07 at 01:52 PM

If it's any help, Caterham's column isn't that dear if i recall, about 80£ish. I'll digout part numbers for you, shouldn't fail SVA either as it's a production part.


snapper - 5/1/07 at 07:10 PM

SVA manual states quite clearly that they want to see not only a crushable bit or sliding bit but also a joint that changes direction between 10 and 30 degrees.
proof of the steerings safety is a big issue if you make your own, use any column from a donor and no problem with the SVA


andyd - 5/1/07 at 09:02 PM

Yes yes yes... I know you all mean well but I'm not building my own car to just have a car. I can go to any dealer in any town and hand over money for a perfectly adequate mainstream car.

I don't want to bolt bits together as in a true kit either because at 37 I'm past building Lego models.

I'm building my own from scratch because I want the challenge.

So please... and this isn't directed at anyone in particular... instead of posting replies to my question that don't actually answer my question but point out, and sorry for this, the bleedin' obvious, can you either wind your neck in or be a little more optimistic.

Now nobody take offence at this rant as I'm just saying that if I'd asked "what's the easiest way to pass the SVA steering column rules" then yes "use one off a type approved car" would be totally correct and the answer I'd be looking for. However that's not what I asked.

Rant over.

For what it's worth, I like the way Paul (907) has made his sliding section so I may do something similar there. I will also be putting in a collapsible part further up. I noticed whilst ironing a shirt this morning that my ironing board base is remarkably similar to the Nova crush section Paul has used too! Plus, I'll be placing joints in the downlink sections to deflect the pieces in the event of a frontal crunch.

So come on guys let not be pessimistic. Lets stretch the boundaries and strive to outdo what already exists!

Of course if all you want is a replica of everyone elses car and to be driving it in this lifetime then that's your choice... I'm expecting to finish my sometime within the next 50 yrs and I can't wait to drive it when I get reincarnated... hopefully not as a fish!

[Edited on 5/1/2007 by andyd]


3GEComponents - 5/1/07 at 10:12 PM

The idea of using Caterham parts was a suggestion to get the same as 907's column but as a cost effective way, it's very simliar, very light, SVA'd and not a lot of money.

I'm in the lucky position of being able to manufacture anything from scratch, having all the machinery on hand, however, sometimes you can end up spending 3 times as much money and then end up with something that someone already produces.

Have a look at the picture and use it to get ideas, it's a very simple way to do it.

Good luck

John

Oops it's too big i'll resize it.

[Edited on 5/1/07 by jroberts]


3GEComponents - 5/1/07 at 10:27 PM

.


andyd - 5/1/07 at 11:19 PM

Thanks John.

My previous post was typed with tongue firmly in cheek.

Looking at both your scan and the Caterham website: -
Firstly to buy all their parts including the bush would be £102.96 and that maybe plus VAT (not sure) and is definately plus postage. Secondly, I think I can seehow theirs is collapsible (as you say, just like Paul's) but I can't really appreciate how theirs is crushable. Also it looks to me that it doesn't have any deflection built in so straight into your face when the lower tube runs out of upper tube to slide into.

Of course I may be missing something.


907 - 6/1/07 at 12:40 AM

Hi All

There's now an edit to my post showing the pic of the column.

Last thing I want to do is mislead anyone as to how it's made.


Andy, since your only the other side of Sudbury from me if you would like a gander you'd be more than welcome.


Paul G