Hi all,
Been reading this forum for a long time now and found it very helpful. I now am stuck and am looking for some advice.
I would like to know how to extend the steering column ie between the donor (sierra) column and the Escort rack. The book is kind of vague. Any advice or photos would be appreciated.
Thanks.

On the standard sierra set up, the bottom of the top part is trianguar, with a clamp and universal joint to the lower section. If you cut the lower section in two, you can insert the ends into some 3/4inch round tube (16 or 18guage), and hence use the tube as an extension (welded in...).

I don't know about extending the upper section. Some people have also added additonal universal joints, but i managed with just the extension tube. Sorry, no photos cos im a cheapskate...!

Don't play around with the triangular part of the column. Extend the lower part only - I used a power lower column because it is not a cast part and can be welded without problems - however you will need the lower clamp from a manual lower column to match the escort rack. The CV joint at the bottom is riveted and will need to be drilled out and replaced with bolts to change the CV joint (rubber disc with 4 holes!)
Rescued attachment Sierra Column4.JPG

Is it essential to change the rubber ring for a proper UJ? Mine is very bent but still works quite well.

The rubber ring is essentially the CV joint, if its OK use it again, you cannot buy it separately fron Ford

Gents (and ladies),
Can I just confirm with you that 19mm x 16swg non-CDS tubing (as used for the back of the chassis) is suitable for use as a steering column downlink extension. It says in the "book" to use tubing of 1/8inch wall thickness (see page 68 2nd edition book, fourth paragraph). I can get CDS of all sorts of sizes and wall thicknesses from Metal Supermarkets and I am going there soon anyway so if 16swg is not "ideal" then what is? Obviously I want to retain the internal diameter which matches the sierra downlink so that they will slip together nicely but I can go for 3/4", 7/8" or even 1 inch outside diameter tubing with corresponding wall thickness if 16swg is too light.

Advice appreciated as always!
Craig.

I know I'll be using rather heavier gauge than 18 or 16 - it'll add weight but there's some things that it's just not worth worrying about weight for, one of the being steering. As I read on someone's website - if you've got brakes but no steering, you're probably going to go into the tree that your car chooses, whereas if you've got steering but no brakes, at least you can pick the tree!

Kingr

I choose the sapling with the large expanse of gravel infront of it!

Has anyone heard of modified racks failing and breaking in half?
When I got hit up the rear by an OAP in a Micra a guy at the repair place told me about a focus they'd had in. It had offside frontal damage, but they didn't spot any steering problems, but a few weeks later the rack broke and the poor lady nearly died.

It'd be nice to put a modded and umodded rack on a big pulling machine to test the tesile strength.

i dunno about other modded racks, but mine wouldnt do very well as it is just slotted together, the mounting bolts are all that holds it together! seems ok though.

i personally wouldnt worry about using 16 gauge tube for the extension, its gonna take a bucket full of force to twist it in two. The weld is the important bit...

Kingr,
Yes I think I'll just get something a bit heavier to be safe. I plan to fabricate it along the lines which Mark Allanson recommended a while back and something like 2.5mm wall tubing should give it a good bit more strength than 16swg or 18swg. I agree that it's just not worth worrying about...
Cheers,
Craig.