installing electric power steering column

[V6quattro]

I'm installing a electric power steering column from a opel/vauxhall corsa C.

I don't know if it's ever been done on a S2 before. It sure is a lot work and i hope it turns out nice

Hope to do some more work tomorrow.

[Henkjan]

cool.

so you ditch the whole hydraulics then?

what about the steering "feel"? I have not heard/read much positive about the e-steering....

[Tonks4x4]

I have a Vauxhall/Opel Corsa C electric column in one of my Typ85 cars. I fitted it as a complete unit and made brackets to fit it.
I like how you are making it so that all the original parts fit.
I had heard horror stories of the little electric contacts breaking inside that control direction assistance.

I purchased a small potentiometer kit from eBay approx £40 which allows you to adjust the amount of assistance the column gives you.

On maximum assistance when parked stationary the steering is so light you can turn from lock to lock with your little finger.

It looks like it is going to be real tight for space. Especially if this was done in a RHD car.


Tonks4x4 - The Land Rover Specialist

[V6quattro]

cool.

so you ditch the whole hydraulics then?

what about the steering "feel"? I have not heard/read much positive about the e-steering....

Yes no hydraulic steering on my car

I have a Vauxhall/Opel Corsa C electric column in one of my Typ85 cars. I fitted it as a complete unit and made brackets to fit it.
I like how you are making it so that all the original parts fit.
I had heard horror stories of the little electric contacts breaking inside that control direction assistance.

I purchased a small potentiometer kit from eBay approx £40 which allows you to adjust the amount of assistance the column gives you.

On maximum assistance when parked stationary the steering is so light you can turn from lock to lock with your little finger.

It looks like it is going to be real tight for space. Especially if this was done in a RHD car.


Tonks4x4 - The Land Rover Specialist

Nice! Sounds good. I also have the potentiometer kit from ebay.

[Error404]

Nice project
I'm interested in how you get on with it. What are your reasons for going this route?


I was going to say Mr Tonks has done it, and also I think Terrybullwon has a Corsa EPAS system on his racecar, but not made to fit in OEM style AFAIK. Maybe this could be a really nice upgrade for people prepared to do some serious modifications

I am curious how the Epas system triggers the assistance, i.e. how does it know when you are putting force on the steering wheel?

[martinws]

Do you attach this onto the original steering column just blanked off? still full of oil or dry?

[terrybullwon]

Yes i have this in mine, great up grade never tried it on road tyres though. Like Tonks said its really light to drive when its dialled right up makes loading the car into a trailer or workshop a dream.

I turned my rack into a wet one with some gear oil, seems to be fine so far

[Tonks4x4]

I used a manual rack with the Corsa column on mine.

Downside is there is more rotations from lock to lock.


Tonks4x4 - The Land Rover Specialist

[Error404]

A potential issue as far as I see it will be that the normal hydraulic PAS rack uses a torsion bar to control how the rotary valve applies the hydraulic pressure to the rack piston, in the pinion. As you apply steering force, the T-bar twists, opening ports in the rotary valve, allowing flow to reach the rack piston. The more force you use, the more the ports open, the more flow is affected. So the T-bar stiffness has a big effect on the amount of steering assist and conversely feedback from the wheels. That is what I modified in my RS2 rack.
I'm not sure how the EPAS system senses input and applies assistance. If it too uses a T-bar (seems likely to me since this is a really simple & effective way to sense proportional rotational force) then you are introducing a damper in the rotary assembly - as the original pinion T-bar is not being used to control the assistance level, it will act like a damper and so steering feel may be reduced.

[V6quattro]

Do you attach this onto the original steering column just blanked off? still full of oil or dry?

I'm not sure yet. I will take the steering rack apart when i have time to see whats the best solution.

A potential issue as far as I see it will be that the normal hydraulic PAS rack uses a torsion bar to control how the rotary valve applies the hydraulic pressure to the rack piston, in the pinion. As you apply steering force, the T-bar twists, opening ports in the rotary valve, allowing flow to reach the rack piston. The more force you use, the more the ports open, the more flow is affected. So the T-bar stiffness has a big effect on the amount of steering assist and conversely feedback from the wheels. That is what I modified in my RS2 rack.
I'm not sure how the EPAS system senses input and applies assistance. If it too uses a T-bar (seems likely to me since this is a really simple & effective way to sense proportional rotational force) then you are introducing a damper in the rotary assembly - as the original pinion T-bar is not being used to control the assistance level, it will act like a damper and so steering feel may be reduced.

I will take the steering rack apart so maybe i can modify the torsion bar. I don't think a manual one would fit because it has a other ratio right?


Also made the adapter to fit the audi colomn to the opel colomn.

[Error404]

Nice work, I like a custom engineering job like this

Manual rack doesn't have a torsion bar the pinion is solid, T-bar is only in a PAS rack. You can make a solid pinion or a really stiff T-bar to convert a PAS rack to manual. A factory manual rack i think is really rare and must be a super low ratio, like 4 turns lock to lock? But converting an S2/RS2 rack to manual will be easy as you don't need to index the rotary valve in relation to the new T-bar so you can just chuck it in and it will work

[Rusty]

My only criticism of the EPAS on the Clio is it's a bit sticky around the straight ahead. Once you're turning, it's fine. Interesting to compare the Dynamique with EPAS to the 172 with PAS. Sane age car but Renault Sport retained the hydraulic system.

[Mcstiff]

THis is interesting but I'd guess costly http://www.dcelectronics.co.uk/Products/EPAS/

[V6quattro]

Nice work, I like a custom engineering job like this

Manual rack doesn't have a torsion bar the pinion is solid, T-bar is only in a PAS rack. You can make a solid pinion or a really stiff T-bar to convert a PAS rack to manual. A factory manual rack i think is really rare and must be a super low ratio, like 4 turns lock to lock? But converting an S2/RS2 rack to manual will be easy as you don't need to index the rotary valve in relation to the new T-bar so you can just chuck it in and it will work

I had a look at the valve today. I noticed there is about 1mm play to left and right
So i just tig welded it together.
Specially after reading this:

http://spece30.com/forum/10-steering-and-suspension/66631-de-powered-steering-pinion-failure

[Error404]

I think that is the best option - you definitely want to remove or lock the T-bar in the pinion

I'm surprised those guys hadn't foreseen this would happen when taking the hydraulic assist off their racks - the steering feel must have felt really weird anyway