D.I.Y Electric power steering

Discussion in 'Mech Tech' started by Keith.H, May 24, 2014.

  1. I decided to make an electric power steering set up for my bay, i still haven't decided whether i will permanently fit it or not, the other half is keen on the idea but i will see how it goes
    Anyway i started off with a Vauxhall Corsa C set up from ebay which was about £40

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    Then i got the inner and outer column from a bay

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    Then it was a case of measuring and cutting the columns to get the EPAS in place while keeping both overall lengths the same

    [​IMG]

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    The top of the Corsa column is solid and fits inside the hollow Bay column, so that was welded up and a roll pin put in for additional security
    The bottom part after the UJ is hollow and very close in ID to the Bay one, @Top Banana Racing made me a very neat joiner so they were then welded together

    [​IMG]

    [​IMG]

    Next it was a case of making an adapter for the top so that the top of the Corsa part had clearance and i could join on the original outer column, then two parts for the bottom part

    [​IMG]

    Then a boot from a trailer hitch to cover the UJ

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    The column itself is now nearly finished, i need to get it in position and weld the top outer column onto the adapter in the desired position which will be with the bulk of the EPAS motor facing forward, then i want to make an additional bracket from the column to the bulkhead.
    At the moment i have a potentiometer type control but there is no way i want to go with that, i want one that is related to road speed, at the moment it looks like i have the choice of two pickups, one driven by the speedo and one picking up from a rear drive shaft, apart from the rear drive shaft one @£200 no one is willing to just sell the pick ups so a bit of investigation is needed.
    Total cost so far is about £110.
    Thanks to @Silver and @davidoft for the VW bits
     
  2. Very nice. Keep us posted on progress!
     
  3. Nice work, the corsa pas is used on loads of rally cars too, because it's
     
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  5. Great bit of engineering. What's next on the R & D agenda? Brazil would be interested in air bags and ABS!
     
    CollyP, Lofty, 1973daisey and 2 others like this.
  6. Thanks for the link, i believe that is where RJES get theirs from for the system they sell, where i get confused is with the pulses they give out, all those show a choice of 4 or 8 but i read here
    http://www.pngclub.com/forum/archive/index.php/t-183363.html?s=19008bc323595dfd414bc6f8763a0713
    that the Corsa ECU needs 15, all over my head unfortunately
     
    Chrisradioman likes this.
  7. Mine too give them a ring they are very helpful. :)
     
    Keith.H likes this.
  8. Will do
     
  9. I could do an ABS system based around porsche running gear ;)
     
  10. Clever stuff Keith.
     
  11. Nice work. :) But I've a question? How well can you hide it behind the dashboard.
    I've seen a couple of these, which were awfully big in the steering column.
     
    Dicky likes this.
  12. It will be original down to the large tongue on the outer column, then the best i can do is have the motor part facing in the same direction beneath it, still be ugly tho :) although i think having the gaiter covering the UJ below is neater than the exposed ones ive seen
     
  13. Okay, thanks for the information. Keep us updated with pics etc :)

    greetz
    Marcel
     
  14. [​IMG] I have been doing the same thing but only have the first layout picture. I will take some more when it is complete. I have done it slightly differently and haven't used the universal joint as I found that both ends fit perfectly inside the original steering tube. I have also chopped the original outer tube to fit top and bottom so it will be all covered. I sprayed the whole power steering motor assembly black so it is a little less obvious. Mine was only £17 including shipping from eBay and half a roll of welding wire. I will be interested to see if you can get a speed sensor system sorted as I only have the rotary switch at the moment.
     
    Majorhangover and Keith.H like this.
  15. I think the use of both universal joints on a short unsupported shaft could be problematical in the sense of a mild misalignment giving the drive a notchy feel as they rotate.
     
  16. The unit will be supported by a bracket to the bulkhead, a lot of weight otherwise on that springy tongue
     
  17. Are you going to use the original rubber steering coupler? I'm not sure it'll stand up well to the force of servo assistance.
     
  18. You may well be right however it only has the same force as if I turned it by hand it's just my GFs arms that will be saved so I hope it will be OK. It's still got an original Vw rubber that has lasted its life so far I think so hopefully it's tough enough to last a bit longer being of the better rubber!
     

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