Steering complete

The steering column is now in place, along with the 10 degrees of deflection required for IVA. Obviously this pic exaggerates the angle;

But it has been measured and should be fine. The upper steering column is fixed at the top with the original sliding bolts which will disengage in the event of a crash. The lower fixing of the steering column is an exhaust clamp, again allowing the crush section to behave as it would have done in the MX5.

The upper part of the lower steering column is then supported by the bearing attached to the firewall. I did wonder why this was here as the column seemed pretty solid without it. But I guess belt and braces never hurt anyone. 

The bottom is standard fare, with the N pattern steering rack mounting welded into place. The left hand rack mount is actually the old MX5 rubber mounting, it fits the Escort rack perfectly. I need to grind down a weld to get it to mount flush though. From memory the right hand rack mounting on the MX5 was just a bolt, so that can't be reused. I'll make something out of metal for that side, not a huge job. 

For the next job, I need to mount the fuel tank. I've found someone on Ebay that makes fuel tanks for around £60, with an extra £15 for postage. He's only in Nottingham so I'll drive up and pick it up.

I need to make a frame for the tank. This is where I've moved quite a bit away from the plans. Because I have no need for a rear frame for the standard Seven tub, I've not actually got anywhere to put the gas tank. The tank sits behind the diff, sticking out of the back of the car. So I need to rebuild the back in such a way that it's as supportive as the original design, but doesn't use the rear hoop. Shouldn't be too difficult...

Steering angle

The steering rack is now in place and bolted up, and I have a problem...

As part of the IVA regs the steering column needs to have a deflection angle. This is so in the event of a head on collision, the steering column doesn't head directly towards the driver. (If only Senna's mechanics had that plan 😢 ).

Unfortunately, me trying to get everything 'just right' means that I've actually lined things up almost perfectly, IE no deflection angle. Which means I need to make some modifications.

The steering rack is in the right place, and cannot realistically be moved. I don't want the steering travel to be different between left and right. The tube between the universal joints can't really be moved either, it has the chassis one side and the engine the other.

What can be moved is the upper steering column. If I move the bottom joint of the steering column out towards the chassis wall, the angle between upper and lower columns will increase. But if I move the bottom joint, the steering wheel will be crooked. Last time I had that I was in an '85 Vauxhall Nova, and the whole drivers side was tipped towards the centre because the front wheel was in the way!

But it looks like I have no option, so I'll chop off the lower bracket and reweld back in the right place. Tomorrows job...

(Tomorrow)

Five minutes with a photo and some powerpoint boxes shows I have 8 degrees deflection with the brackets as I've welded them. So I've chopped off the bracket that is in that photo, and I will need to move it to the right just an inch or so to get the 10 degrees.