Steering column joints and splines

malcolm · Jun 29, 2007

Not sure where to start on this one. I want to modify a steering column by removing the existing flexible joints and fitting a couple of universal joints. It needs to be shifted a little to clear a carburettor.

I can strip the system down to the shafts. From there I've been struggling to find a machine shop that will put splines in for me, and to chose which universal joints to use.

What type of machine shop would have a splining machine? Or has anyone found UJs that clamp onto a D shaped tube like the ones you see in modern cars.

MrFluffy · Jun 29, 2007

Tool to do that is called a broach. Which probally wont help you much as all the companies listed under "broaching" tend to be big multinationals that cant be arsed faffing round with a project. Can you not adapt a link shaft from another car, and get a uj made up that has the fittings already for the dissimilar sides? A prop and steering specialist can make up a custom uk with different yokes on it...

MrFluffy · Jun 29, 2007

Might start you off thinking too :-
http://www.nfauto.co.uk/steering_uj.htm

rusty69bus · Jun 29, 2007

http://www.rallydesign.co.uk/catalog/product_info.php?products_id=11805 have a browse across hot rod parts places try wisbech engineering

malcolm · Jun 29, 2007

Thanks for those - I'd been looking in totally the wrong place. I bet the drag racer builders that shortened my axle will be able to get it machined.

andrewg1323 · Jun 29, 2007

No possibility of adapting something already in existance? 70's fords used a similar coupling, was a pain in the ass when i changed the capri rack!

malcolm · Jun 29, 2007

Problem is the joints on the steering column and rack (both have a very allowable angle) are welded at the moment so will need cutting off, so I'll be stuck with having to attach something to them. Could make a mechanical fit then weld, but would be stuck if they ever needed replacing again. The new column section is cheap enough, so just a case of getting the other bits machined and buying some joints.

Agree splined joints are a pain though. Have you seen the modern joints with the cam shaped spacer that clamps onto a flat in the bar? Those are really cool. Hmmm, wonder if those are available joint only as I can make a flat in the tube no trouble. Normally they're welded to a shaft.

andrewg1323 · Jun 29, 2007

Give ford a ring and ask for a MK5/6 Escort steering coupler thye're like the ones you want
My copy of the parts catalogues not here or i;d look for you

malcolm · Jun 29, 2007

Excellent, thanks. I'll pop into a Ford dealer and have a look at their catalogue. Definately the easiest solution to fit joints with the cam type attachment.

Alex · Jun 30, 2007

This thread reminds me of Ayrton Senna, they believed his steering column broke because of a bad weld.

malcolm · Jun 30, 2007

It's definately a bit that doesn't want to be got wrong. The design rule for welding those things is to have a mechanical connection that will work if a welded connection were to fail. "D" shapes are common.

Alex · Jul 1, 2007

In the event of a crash they must design car steering columns so that a front impact wont send the column straight through your chest if you see what I mean.

I imagine the universal joints would prevent that situation from occuring.

andrewg1323 · Jul 1, 2007

Steering colums are required to be collapsable by law yes, this its typuically done by maing the column 2 sleeves one inside the other that are only jeld together lightly so if you hit the wheel the tubes slide inside each other

MrFluffy · Jul 1, 2007

Aye, the collapsable bit is generally done by a lattice section to the outer tube in the column, and by a two section shaft inside that allows it to telescope. The lattice section collapses to absorb the energy before the telescopic section runs out of travel, but generally after 6" of collapse and the resultant deformation of the front crumple zones youve got bigger things to worry about than the column poking you...
Fitting my homebuilt car with a column out of a corsa b, along with a stimulator so I can run the corsa electric power steering without pipes from the back of the car (rear engined) up to the rack.
Malcom, while your at changing the uj's etc, could be a good time to do this if it floats your boat...

Martinslost · Jul 10, 2007

pug 106 power steering using the cam type UJ - rack connection. To be honest even though I changed my rack a couple of weekends back I can't for the life of me remember seing how the UJ attached to the column, but I think it was welded somehow. I'm tinkering again tonight so will have a look, i.e. standing on my head under the drivers side dash. Not sure of other makes are like it but pug / citroen used splined UJ's for manual steering and cam types for power steering as a general rule, although there were some exceptions.

that is of course unless you've already sorted this. Otherwise I do have a non power steering 106 colum which has a splined UJ on the bottom of it if ou need a pic or anything.

malcolm · Aug 22, 2007

Finally got around to finishing the column. I chose the Ford Fiesta joint in the end as it has a hex shape at one end which would be easy to prep without going to a machine shop.

I used a dividing head to make the hex with an angle grinder with a bit of bar attached so it would grind at a consistant angle.

Worked out accurate enough for the job. That's the hex side of the joint sorted.

Splined shafts are available from Car Builder Solutions but are only splined at one end. The idea is to buy 2 and weld them together.

I prepped the joints to a V shape and welded two shafts together. The sleeve that will go around the shaft is drilled for plug welding.

Plug welding completed. For a steering column the belt and braces approach of a sleeve is really important - it's not good to have them snap.

A bit of finishing off and the whole thing assembled.

This was my second attempt at the steering column. First attempt used the strange original Renault joints which have a bit of rubber inside them, but I felt the column wasn't stiff enough with those.

Alex · Aug 22, 2007

You have the same Bosch grinder as me, got to say its well made and the metal casting is superior to any other including the big expensive names.

andrewg1323 · Aug 22, 2007

looks ace and can hardly tell its not OEM equipment

Steering column joints and splines

malcolm

& Clementine the Cat

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