andyd
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| posted on 4/1/07 at 04:30 PM |
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Fabricating a steering column
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?
Andy
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oliwb
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| posted on 4/1/07 at 04:32 PM |
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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.
If your not living life on the edge you're taking up too much room!
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scottc
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| posted on 4/1/07 at 04:32 PM |
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Would it be easier to put 2 Universal Joints in it instead?
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andyd
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| posted on 4/1/07 at 04:35 PM |
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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. 
Andy
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Agriv8
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| posted on 4/1/07 at 05:21 PM |
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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
regards
Agriv8
Taller than your average Guy !
Management is like a tree of monkeys. - Those at the top look down and see a tree full of smiling faces. BUT Those at the bottom look up and see a
tree full of a*seholes .............
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Marcus
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| posted on 4/1/07 at 05:27 PM |
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Yes, you're ok with an angled column, but don't forget you still need a collapsible steering wheel boss.
Marcus
Because kits are for girls!!
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andyd
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| posted on 4/1/07 at 07:32 PM |
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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?
Andy
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muzchap
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| posted on 4/1/07 at 08:22 PM |
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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
------------------------------------
If you believe you're not crazy, whilst everybody is telling you, you are - then they are definitely wrong!
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907
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| posted on 4/1/07 at 09:59 PM |
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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
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andyd
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| posted on 4/1/07 at 11:11 PM |
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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?
Andy
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907
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| posted on 5/1/07 at 12:43 AM |
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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
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3GEComponents
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| posted on 5/1/07 at 01:52 PM |
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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.
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snapper
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| posted on 5/1/07 at 07:10 PM |
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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
I eat to survive
I drink to forget
I breath to pi55 my ex wife off (and now my ex partner)
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andyd
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| posted on 5/1/07 at 09:02 PM |
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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]
Andy
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3GEComponents
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| posted on 5/1/07 at 10:12 PM |
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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]
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3GEComponents
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| posted on 5/1/07 at 10:27 PM |
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.
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andyd
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| posted on 5/1/07 at 11:19 PM |
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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.
Andy
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907
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| posted on 6/1/07 at 12:40 AM |
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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
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