1994 - Ford Escort Cosworth - power steering fluid tank

Not that I've seen. Although I'm not sure if it's permitted practice on rally cars any more.

Most of the ones I've seen on track cars don't even have the vapour hose I'm putting on. Just a fuel hose open to everything.

Mine will have a little stay coming off the cage to hold the tube / vapour hose in place, and take up the weight.

Leans reasonably OK with the odd splash, but I'm sure will yellow and degrade from it.

I know. Need to find more opportunities for them 😁

Ah irritating to say the least. Sure you'll have it sussed quick smart though.

This model shows the issue



the column (black box) goes through where the balance bars are

the master cylinder is actually pointing under the centre line of the balance bar in neutral position. This is ok for the standard position as it still stays within the cone of action for the master cylinder.



The new position however has put too much angle on the push rod and locks.

Could you move the bulkhead bearing down to get enough clearance?

So i took some dimensions and mocked things up in CAD.

Current design with clash of column on balance bar



I then tried lowering the upper mount



you can see there is a reasonable change in angle and will result in the steering wheel sitting a fair bit lower.

Calc shows the angle change drops the wheel centre by about 50 - 70mm

if I drop the bottom about 25mm i get this



surprise, the steering wheel will go up.

so i need to drop both to get back to the original angle back



Certainly looks like an option to resolve it.

A drop of about 15 - 20mm at the bottom hole should be fairly doable and there is already about 10mm room to drop within the existing bulkhead cut out.

Boom. Sorted it.

Clearance, and it only took spending money and redoing the whole steering column

P1060351 by jono_misfit, on Flickr

looks tighter than it really is, but clears. I'm going to get some 20mm plastic tube and sleave the triangular section to ensure there's no opportunity for the balance bar to snag on it.

P1060352 by jono_misfit, on Flickr

how did I get the clearance... by doing this to the bearing

P1060353 by jono_misfit, on Flickr

which drops the column right to the bottom of the bulkhead hole

P1060354 by jono_misfit, on Flickr

P1060355 by jono_misfit, on Flickr

it looks like its resting on the lip, but there are a few mm's clearance.

bottom sorted, now to sort the upper column.

my housing is from a Granada rather than an escort, and the top section is different. At least I assume it is as otherwise the column doesnt fit!

There's a casting that goes on the end I wont be using,

P1060357 by jono_misfit, on Flickr

and this tube needs shortening.

P1060356 by jono_misfit, on Flickr

there's a bearing in the casting to ensure the column sits in the right place, and has minised friction (the sierra colum i've been using just has a large lump of nylon to do this which feels quite draggy.

P1060358 by jono_misfit, on Flickr

worked out what I needed to make

P1060359 by jono_misfit, on Flickr

dulled my arms a bit

P1060360 by jono_misfit, on Flickr

turn turn and turn some more

P1060361 by jono_misfit, on Flickr

end result

P1060362 by jono_misfit, on Flickr

added some bolts to fix the aluminium part into the steel tube and bolted back into the car

P1060363 by jono_misfit, on Flickr

Everything still clears and steering feels good with no slop. However now I can feel the rack bushes moving a bit, so will be turning up or buying some aluminium inserts to resolve.

The other thing I noticed was how much flex there is in the convoluted tube section. Its fairly thin and a pull on the steering makes it deflect. I appreciate this is for column collapse, but I can see me remaking it at another point to eliminate the flex.

redid the bearing mounting hole

P1060364 by jono_misfit, on Flickr

I just need to do something to seal the gap and prevent water ingress around the bearing.

P1060365 by jono_misfit, on Flickr

My shuffle round of things on the mezzanine meant i think I've foudn the missing air duct feed for the windscreen. Hopefully. Will see if its the right part i've found next time I pull the dash.

Escort will be back on stop now until I get the postman pat van finished.... unless the compressor doesnt turn up.... then I may end up oni the escort again next time.

coming along again, i saw your comment on Tobys thread on passion ford the pug 205 4X4 cosworth i bought his old gearbox and other parts off him ages ago.

any updates on your car?

i have finally got the 2 pallets of parts that i have had in the UK for the last few years, they are being couriered to a depot and then shipped out to me should get them in about 12 weeks