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.
What’s left of the original Corsa UJ 😮 Took about two hours to make this as it needed welding and grinding carefully.
It fits…
Next step is to get it all mounted up in the car and check lengths on the pinion and column are right.
Rallye Project 
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