The saga of my 21 year old polo continues

I have done pretty well to be fair finding replacements for all the rusty parts, shes all under-sealed and ready to reassemble.

The stumbling block seems to be the high pressure PAS hose that links the pump to the rack.

Its a bent tubular item with two flexi sections. Mine has rusted through on the banjo weld.


There are endless aftermarket ones available in Germany..... unfortunately they are for the left hand drive variant which means the pipe isnt long enough....

VW tell me they no longer make the part.

Can I make my own somehow? Could perhaps buy the LHD version and extend the steel tube?

This is what it should look like - Long steel pipe after short flexi

Description

But all the LHD ones are like this

Description

Any thoughts?

I's usually just steel pipe with the correct fittings isn't it? A larger bore kunifer type brake pipe might do, though I'm not sure about the materials mismatch or how to attach the fittings. But a hydraulics place will be able to knock these up really easily I would have thought

https://www.youtube.com/watch?v=RGJ5zC7lhz8

[Edited on 30/6/22 by coyoteboy]

Teg, can you not find a local agricultural engineering company to ask?
Strikes me they probably come up against odd-ball, unobtainable quite regularly.
Cheers, Pewe.

Have you tried GSF Car Parts?

https://www.gsfcarparts.com/

Often pretty helpful for parts for German, Swedish and French cars. They mave have New Old Stock of the item you need. They have plenty of locations and do delivery as well. Helped me out with Peugeot 205 GTI parts (that Peugeot no longer make) before.

quote:

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Originally posted by nick205
Have you tried GSF Car Parts?

https://www.gsfcarparts.com/

Often pretty helpful for parts for German, Swedish and French cars. They mave have New Old Stock of the item you need. They have plenty of locations and do delivery as well. Helped me out with Peugeot 205 GTI parts (that Peugeot no longer make) before.

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Hmm AN fittings might be an option. Hadn't thought of agricultural engineering. Will ask around.

Wonder if its possible to just extend a new LHD version.

Air Con must have been an expensive extra when the cars were new.

Peugeot 205 GTIs gave you an option for PAS or Air Con, but not both. Not enough space in the engine bay apparently.

quote:

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Originally posted by nick205
Air Con must have been an expensive extra when the cars were new.

Peugeot 205 GTIs gave you an option for PAS or Air Con, but not both. Not enough space in the engine bay apparently.

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Certainly must have costa whack brand new.

Digital climate control would have been an executive saloon feature back then.

Self levelling lights seems very elaborate for a hatchback too. Understandable on a large estate or a car that will be used for towing.

A thought on the PAS pipe, if you have a friendly garage you could ask them what they'd do. Must be something garages come up against.

I expect the banjo will be brazed on rather than welded. If you have access to oxyacetylene, or maybe even a MAPP brazing torch, you might be able to knock the banjo off the end. Then you can assess the damage to the pipe and either cut and extend the pipe (sleeve and braze or butt join with tig), or just braze it back on with some filler over the hole.

It's 'high pressure' in power steering terms, but it's quite piffling in industrial hydraulics terms. You may struggle to find someone who would warrant their work modifying what you have though...

Could you convert it to manual?
Years ago I worked for a company supplying pas assemblies to various companies including Nissan and Lotus. The hoses were very specialised, some of the fluids could be quite aggressive. I guess you could get a company to make something up that would work, the steering feel may be a bit different and hose life could be compromised.