Posts Tagged ‘Corsa C’

Corsa C EPAS Conversion

Posted: 27th August 2013 by asteriskr in Rallye 16v
Tags: , , , , , ,

Have spent a bit of free time over the last few weeks painting and prepping the car for reassembly. As part of finishing up this thread from my perspective, here are some pics of the Corsa C EPAS conversion for future reference.

Corsa C

Corsa C]

Corsa C

Long Pause

Posted: 28th October 2012 by asteriskr in Rallye 16v
Tags: , , , , , , ,

Been up to my eyeballs in work for the last month or so and getting very little time to work on the car. In fact haven’t been down to the garage for more than a few hours in all that time. Managed a few hours this afternoon which was a welcome relief.

In the mean time I’ve been working on a few little bits and pieces that I could do late in the evenings. First up I needed a mounting bracket to fit the Dash2 in the instrument binnacle. Following several rough cardboard versions, I made one prototype in alloy before the final one was made:

Photo

Photo

Fitted together as per the photos, there’s an access hole in the back of the binnacle for the two parts of the loom to connect. I’ll put some edging around it so that the carbon doesn’t chafe the wiring.

Photo

Photo

After a lot of planning and an initial failed attempt, finalised the steering wheel wiring. I ditched the earlier cable which seemed to be a coiled keyboard lead that had been purchased (although it came from a reputable motorsport electronics specialist) – the signal wires were just too flimsy and I could see no way it would last in a rally car build. The new one was sourced from a specialist in the Netherlands. It’s securely anchored to the wheel giving the wiring plenty of strain relief. Fitted with Cannon ITT Neptune connectors wired in and ready to plug and play 🙂

Photo

A while back some one PM’d me to ask if you could fit a Corsa C EPAS without having to cut the dash. I think I said yes. What I should have said was no, but you don’t need to cut too much out to get it to fit.

Photo

As you can see form the photo unfortunately the flocking that Raj did is flaking off in big patches. This was one of his early ones, I don’t think he’d perfected the plastic priming process then. Hopefully it won’t be too much of a job to get it redone. With the dash in, it was time to check out the new drivers view…

Photo

Finished off the day chopping loads out of the back of the dash. No heater in the car and heated screen going in so there’s no need for any of the built in ducting. I had already cut a kilo out of it reckon that there’s quite a bit more that come out of it.

Dash for Progress

Posted: 5th September 2012 by asteriskr in Rallye 16v, Welding
Tags: , , , , , , , , , , , , ,

About to become exceptinoally busy with work which will put a dampner on much progress in the coming month or so and as a result I am trying to make a bit of a push on the car. I suspect the biggest development is to finally decide the direction for the build, which is now intended for stage rallying. So with that in mind picked up a few more bits Peugeot Sport France (PSF) style sumpguard and mounting that will need to be welded onto the front of the car.

Sumpguard

Sumpguard

Wilwood hydraulic handbrake conversion kit was next. The current handbrake has now been drilled with a 2.5mm hole uinto which a locking pin (bit of stainless steel bicycle spoke) can be insterted to make it a fly-off lever by disabling the ratcheting mechanism and will now need a tab welding on so that the bracket that drives the piston can be attached. I need to have a look at leverage ratios to make sure I mount it properly.

Hydraulic Handbrake

Hydraulic Handbrake

My friend Stu who makes a good living out of welding day in day out kindly did the honours on my EPAS column:

Which has meant that I can reassemble the unit and get it back in the car. I just need to finish assembling it with the support bearing and tube that fits near to the boss. What a mission this has been.

EPAS

Welded in the rear mounts for the fuel cell container – the alloy for the retaining straps turned up today too. Looks a bit messy at the moment, but it will clean up nicely.

Fuel Cell Mounting

Steering Column Update

Posted: 8th August 2012 by asteriskr in Rallye 16v
Tags: , , , , , , ,

Here’s the modified steering column and Lifeline weld-on boss all machined and ready to be welded up:

Column

The top hat acts as the bearing carrier for a roller bearing that supports the column inside an outer tube. It needs to be removable to replace the bearing and will be held in place with a roll pin. The weld-on Lifeline steering wheel boss and column are also drilled through so will be mechanically joined as well as welded.

Column

Further EPAS Work

Posted: 26th April 2012 by asteriskr in Rallye 16v
Tags: , , , , , , , ,

Managed a couple of hours this week due to a couple of strokes of luck giving me some time back, so cracked on with work to get the EPAS fitted. The Borgeson double UJ has two what are known as DD fittings of different sizes ( 3/4″ DD / 1″ DD ). I ordered mine to get the closest match to the Quaife pinion and then because they didn’t do one to match the splines on the Corsa column, I went for the biggest DD size so that I could trim the original Corsa UJ down to create an insert into the DD.

Quaife pinion modified to fit one end of the UJ.

EPAS build

What’s left of the original Corsa UJ 😮 Took about two hours to make this as it needed welding and grinding carefully.

EPAS build

It fits…

EPAS build

Next step is to get it all mounted up in the car and check lengths on the pinion and column are right.