GT-Forte GTs40 build

[David]

A few little updates, nothing major.

Made up spacers for the pedal box, just need to get the steering column finished and I can sort the final location. On that note I've found UJs Universal Joints Steering Racks Classic Cars who do suitable UJ's so that I don't have to mess about welding the original Corsa B to an Escort Rack compatible spline. I've asked a friend to nip by some time when he has a chance so should have a pair by next year.

Bought a load more items, now have a full complement of COP's, a fuel pump, swirl pot, loads of aerospace type fast flow AN connectors and some radiator mounts.

Got a load more metal too, although the fake ribs for the sills didn't survive TNT

Anyway, threaded some bar and made spacers for the throttle bodies

I've started on the inlet manifold but lots of machining required!

 

[Darrin]

Just realised while looking through I forgot to mention I trial assembled the front suspension.

Missing the track rod extensions (escort rack), the camber adjuster locknut and all of the nuts and bolts are wrong. Still gives an idea of how it fits together.

I also really need to sweep up the kerf!

Shouldn't there be a nut between the ball joint and the gold anodized insert?

 

[David]

Shouldn't there be a nut between the ball joint and the gold anodized insert?

Yes. But it's a very tight nut due to being stamped in slightly and I didn't want to damage the threads by winding it on and off umpteen times so left it off.

 

[Darrin]

Yes. But it's a very tight nut due to being stamped in slightly and I didn't want to damage the threads by winding it on and off umpteen times so left it off.

Same on mine. Very tight.

 

[David]

Haven't done much recently due to it being too cold to work in the garage. Anyway been a bit warmer and a few more bits arrived so actually done some work!

Firstly it turned out that I had *just* enough from the D section to cut the bits I needed from the straight remnants, aluminium warehouse still sent me some more though so now I have 8m of D profile I don't need!

As per my previous post I purchased some steering UJ's from Kiley Clinton (Steering Racks Rack and Pinion Steering Kiley Clinton), for anyone wanting to use the 'Corsa B' EPAS column you need a KC1113/D which converts it to a 9/16th / 36 spline along of course with the UJ for the bottom which is KC1113, just a 9/16th /36 spline both ends.

Top fitted fine, bottom clouted the frame.
After some consideration I decided to change to the same layout as the later frames, so remove the rack and out with the power hacksaw.

20 seconds later...

Oooh er!

In hindsight bit of a shame I didn't cut closer to the chassis on the left of that picture, that way I wouldn't need to cut a fresh piece of tube but could have re-used the cut section. Oh well.

So back in with the rack and showing roughly how it will be (and how the cut section is only a tiny smidge too short!)

Just need to clean it up and weld in a new piece, need to wait for my next 'noisy' working day though!

Then I made up a 'mock' column (its just aluminium bar, turned down so it fits into the UJ's) and fitted it so that I can get the footpedal location finalised.

I also started work on the rear bulkhead, I'd been thinking about this some time and I've decided I'm going to go for looking 'original' so need to take up the difference between the side sections and the main hoop. I bought some square tube and have started to cut it to size. It'll then be attached to the chassis and the bulkhead on top. Haven't made my mind up how I'll attach it yet, I've worked out I can rivet it through a 9mm hole if I make up a special extension to the pop-riveter.

In other news my ECU is due for delivery tomorrow and I've got 4 out of the 8 velocity stacks / trumpets and an air temperature sensor by the simple expedient of buying an airbox off a GSXR1000 (ie the same donor as the throttle bodies).

 

[Bill Musarra]

David,
I am asking several of the UK guys about their Corsa steering setups. I have several questions. Where did you source yours. Which units are the better of the ones that are cmpatible and why?? I have found a few on Ebay for around 45-76pounds($75-110) and as much to ship it here to the states. Some are bare collums and others have all the parts that are on the colum including the adjustable height mechanisms. I am assuming you are using, or plan to use an aftermarket controller like those from Australia. Are there any there in the UK. The units in the US(unisteer etc.) are complete steering units that list for well over $900 and are geared toward the high end cars, as they have to be installed by a certified company or one of their sellers. If I had unlimied funds I might consider them but my funds manager has slowed down the withdrawal frequency. so I am looking for the best way to do this. My 40 is more or less finished off so the complexity of mounting it is a little more difficult. My dash is simi removable as I used mechanical guages, so I can get the dash out of the car but not unhooked without a lot of dismantling.Apreciate your imput.

Bill

 

[David]

Hi Bill.

Mine was sourced off ebay.
Corsa 'B' is better because its shorter.
Corsa 'C' is cheaper because everyone want's the 'B' and it's not as suitable but on the plus side the ECU is attached rather than separate so it comes with it more often.

The 'B' EPAS column is rarer as not all cars had them, it was IIRC only on the 1.2, so lots of manual columns available.

In the GTs40 you remove everything so that you're left with just a short (from memory about 20cm) length of column with a motor attached, the adjustable height etc goes.

You *need* the ecu but then the 'controller' does nothing more than feed a speed signal to the ECU.

Major downside to them is that you need a substantial dash to bolt it to as unlike in a 'normal' steering setup the force of the power steering has to act on where the column is bolted down. This may need reinforcement of your dash area.

 

[Renato]

Hi David,

That is a good point about the torque from the electric power steering being transferred to the mounting points. There was no other way to route the steering shaft than to cut the chassis?
Can you clarify about the classic look of the bulkhead, what is the difference?

Hi Bill,

I'm using a steering column from a Toyota Yaris (I think 2002) and it is readily available with the ECU. The ECU needs a speed signal that I'm providing from a small signal generator that I made. I'm still in a process of figuring out how to mount it. I bench tested and it works fine.

Renato

 

[David]

Renato, your chassis is different to mine... Yours (and Darrins) go the way I plan to make mine, Darren changed the design after mine. I couldn't see any other way, mostly because then it would have forced the foot pedals further back which then meant they'd have to go left (to avoid throttle / chassis interference) and then they'd have to go even further back (to avoid steering column interference, again!)

I want it to look kind of like this (Shamelessly stolen from gelscoe)

Obviously it's not going to be identical because well it isn't an original and the proportions are wrong but basically panel the outer sides first then the centre over the top rather than make it in one piece, staggered or flush.

 

[James Harvey]

Hi David

I've got loads of steel in the garage at the minute . Let me know if you'd like a piece that's slightly longer than what you're working with and I'll stick it in the post.

I am assuming you are using, or plan to use an aftermarket controller like those from Australia. Are there any there in the UK.

Is this what you're looking for Bill, here?

 

[Mick Ridley]

Hi David,

Good to see you back on with your car.

What I did to overcome the problem of the steering column getting in the way of the pedals, was to make a short shaft between the steering rack, and the UJ, this will lift the steering column up and give more clearance for your feet, and pedals

Also I was going to use Granada uprights, but I have bought the alloy Rally Design ones. One of thier advantages they have is that the control arms have tapered spacers in them for the ball joints, the spacers can go in either way, from the top or the bottom. which means that the ball joints go down into the control arms, which allows you to raise the steering rack, which again will give more clearance

 

[Bill Musarra]

James,
That looks like just what I may need if I go the Corsa route. May need some help with obtaining a unit. There are several listed on the UK Ebay. Some stripped down, others with all the attachments including adjustable colums. Going for $75-$110 with as much for postage.

Bill

 

[Renato]

Hi David,

Where did you buy steering universal joints? One connecting to the rack.
Also, how happy are you with the radiator quality and fit?

Regards,
Renato

 

[David]

Hi James,

I've got loads of steel in the garage at the minute . Let me know if you'd like a piece that's slightly longer than what you're working with and I'll stick it in the post.

don't worry about it, I needed some steel for other bits so bought a few lengths.

 

[David]

Hi Renato,

Where did you buy steering universal joints? One connecting to the rack.

See post #265: http://www.gt40s.com/forum/gt40-build-logs/35077-gt-forte-gts40-build-14.html#post398511

But to save you the effort

As per my previous post I purchased some steering UJ's from Kiley Clinton (Steering Racks Rack and Pinion Steering Kiley Clinton), for anyone wanting to use the 'Corsa B' EPAS column you need a KC1113/D which converts it to a 9/16th / 36 spline along of course with the UJ for the bottom which is KC1113, just a 9/16th /36 spline both ends.

Also, how happy are you with the radiator quality and fit?

Happy, have yet to actually fit it but looks decently made.

 

[David]

Suppose I should put an update too!

Not a lot done still, far too cold or been busy when its not been. Also my baby girl is going through a developmental growth spurt and decided to go from a really good sleeper to a crap one so rather curtailing evening work.

So mostly been doing stuff I can do 'in the house', so bought a megasquirt, in kit form so started with this

Now fully populated and seems working, its the MS3 with MS3X so I can run the COPs and full sequential injection.

Started on designing and buying bits for the engine wiring loom, the car one can wait until later but need to wire up both the COPs, injectors and sensors. Having grief worrying about wiring (temperature) ratings though!

Also have done some 'garage' work, started machining the right angle adapter I need for the water pump outlet. Nearly finished it but not taken any pictures.

 

[James Harvey]

Hi David

I think the MS3 with MS3X looks pretty cool. Should give you lots of flexibility on how you're going to run your engine.

Just wondered if you're planning to use the JimStim / JimStimX to test it?

 

[David]

Haven't made my mind up about it yet, I can test a whole load without it but would probably come in handy to validate things.

 

[Keith Stafford]

David

I just got my Corsa C power steering today (without connectors), would be interested to know if you got your rpm/speed sig gen working,... do you take an input signal to give you speed, is it a pulse from somewhere? I would also like to know if you have the pin-outs for the PAS connectors? You can see some pix on the Belfast Tornado build log.



Keith

 

[David]

Hi Keith,

I've not started on one, I know what to do though, I'll be using a microprocessor the only issue I have is creating 12v from the 5v and that's not that big an issue.

I've got a speed sensor on the gearbox (01E), I've not yet looked into what type of signal I get from that however.

Unfortunately it seems while I know where the ECU is I've misplaced the wiring, you could try asking this guy nicely though (and might also find it of interest) Corsa C Electric Power steering (EPAS) - blog - Seventh Heaven - Locost - Haynes Roadster otherwise I'll check when it turns up...