ayoungman
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| posted on 11/2/05 at 09:30 AM |
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steering shaft
I want to lengthening the sierra steering shaft as per the Avon book. I don't fancy paying for one from tiger. Is there anything I need to know
before doing this. Obviously, I'll adopt a "belt and braces" approach, but what have others done.
"just like that !"
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JAG
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| posted on 11/2/05 at 11:01 AM |
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I found a piece of close fitting steel tube of sufficient length - I think it was electrical conduit tubing.
I cut the ends at an angle - to give some mechanical grip if the welds failed. Then welded that to both sections. High heat, low wire feed to ensure
plenty of penetration 
Then I drilled through the tube were it overlapped the original shaft in two places (at both ends). Then I 'puddle' welded the two
again.
Finally I drilled all the way through the tube and the original shaft (in the overlap area but at 90 degrees to the 'puddle' welds) and
put an M4 bolt through with a nyloc nut on the end.
The nuts are not tight - the idea is to use the bolt to check the weld integrity. If the bolt/nut rotates in the hole (through the shaft/tube) the
weld is still holding.
It's a belt & braces method but I don't fancy the consequences if it fails at speed 
Justin
Who is this super hero? Sarge? ...No.
Rosemary, the telephone operator? ...No.
Penry, the mild-mannered janitor? ...Could be!
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DarrenW
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| posted on 11/2/05 at 11:38 AM |
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Make sure the tube has good wall thickness. Be careful when drilling holes and puddle welding. My uncle is coded welder and does not recommend this.
It is easy for the tip to arc out on the outer surface first leaving a void in the middle = weak spot.
The jury is out on drilling after welding to fit the M4 bolt - doesnt this weaken the assembly??
seeing as none of the DIY shafts are subjectied to torque durability testing (std test in steering column production) you must satisfy yourself that
you are happy with the end result.
You cant have enough penetration
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JAG
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| posted on 11/2/05 at 12:32 PM |
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Agree with everything you say Darren.
My tube had a wall thickness around 3-4mm.
For puddle welding I drilled the holes to 13mm diameter through the tube, letting the tip of the drill penetrate the solid shaft.
Proceeded to weld from the centre of the depression outwards in a spiral form - deliberately to reduce the chance of voids as per your Uncles
recommendations.
Max power, low wire speed - glowed for 1-3 minutes afterwards.
HTH
Justin
Who is this super hero? Sarge? ...No.
Rosemary, the telephone operator? ...No.
Penry, the mild-mannered janitor? ...Could be!
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chrisf
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| posted on 11/2/05 at 02:07 PM |
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quote:
glowed for 1-3 minutes afterwards.
How did your U Joint hold up afterwards?
--Chris
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wilkingj
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| posted on 11/2/05 at 07:34 PM |
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I used a Steering Drag Link off a Land Rover (90 or 110 - Coil sprung model, the one from the steering box arm to the Wheel)
The Sierra shaft when cut in half fits almost perfectly in the LR shaft hole. I just opened up the two existing slots in the end (where the track rod
end goes) and welded along there. Also drilled a hole before I put the sierra bits in, and then puddle welded that.
This is a tube with about a 4mm Wall thickness. If its good enough for steering 2 tons of Land Rover, it will be OK on 600Kgs of Viento.
1. The point of a journey is not to arrive.
2. Never take life seriously. Nobody gets out alive anyway.
Best Regards
Geoff
http://www.v8viento.co.uk
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Peteff
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| posted on 11/2/05 at 08:48 PM |
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How did your U Joint hold up afterwards?
If you cut the sierra downshaft in the middle you are 5" away from the u.j. I don't think it's going to get warm enough to do it any
harm. I noticed in the spares shop near us they do the rubber donut bit separate, you grind the rivets off the old ones and replace them with M8
bolts. When I did my first one I just cut the shaft pushed the ends in a tube and welded round it and it's still alright so I think the next one
will get the same.
yours, Pete
I went into the RSPCA office the other day. It was so small you could hardly swing a cat in there.
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wilkingj
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| posted on 12/2/05 at 12:24 AM |
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You dont have a piccy of the donut, or a shop name / phone number.
Mines fine but it is a bit old.
I was a fair way away from the joints wth the welding..
1. The point of a journey is not to arrive.
2. Never take life seriously. Nobody gets out alive anyway.
Best Regards
Geoff
http://www.v8viento.co.uk
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the moa 2
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| posted on 23/2/05 at 12:06 AM |
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Im also looking at my steering colum and finding that it needs extending due to it fowling the dash board and also for a better driving position due
to a bit of a lancky situation going on.
I have enclosed a picture of the sierra column which is sitting in my luego locost chassis and wanted to know where people recommend cutting and
welding ...
position 1 or 2 or none ?
 
steering column circles
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