Welded steering column

[dax]

Hi, I am based in Nelson and at the early stages of complying my UK built DAX Tojeiro (www.daxcars.co.uk/tojeiro/index.htm). After a complex run of compliance issues with various inspectors, none of whom are now inspectors, we have a new chap who is very much more willing to work to the official regulations!

Now, the question is that the steering system is a Ford Sierra collapsible colum the sliding output end of which is a triangle shaped shaft. To the end of that has been welded by DAX a short length of spline which in turn takes the first of two universals. Then there is a length of about 300mm of shaft with a spline on both ends and the rack end is joined with a second UJ. If there's any confusion I can post a piccie.

The welded spline was TIG'd by DAX who hold all of the relevant UK certification and I have also had it crack tested by Southern QA Ltd in Ch-ch on the instruction of the second of the compliance chaps. But the manual says welding is a no-go.

So if there no way that this is acceptable, I'll need to totally re-engineer the colum to accomodate one with the correct spline. But I have to date been unable to find any vehicle that has the same spline and am at a crossroads with what to do. Suggestions would be most appreciated.

[Justin]

Hi there

You're quite right, the Hobby Car Manual precludes welding a steering shaft, unless there is no other alternative and where the LVV Technical Advisory Committee approves of the modification, or where the vehicle that was built, or was fitted with the welded steering shaft prior to January 2007, and where the requirements of 18.9 of ‘Chapter 18 – Attachment Systems’ have been met.

In your particular case I can't say for sure, but it's likely that you will get some helpful advise from either a local steering or vehicle modification specialist, or from one of the many other specialists throughout NZ. If you'd like to give me a call I'll happily point you in the right direction - call me on [phone].

Cheers, Justin

[dax]

Thanks Justin, does it make any difference that the vehicle was on the road in the UK way back before I bought it out to NZ in 2002?

Local outfits want to take the vehicle in and do the job themselves, been quoted absurd figures.

[Justin]

Hi again

Yes - this means that it can be treated differently - where the vehicle was built, or was fitted with the welded steering shaft prior to January 2007, and where the requirements of 18.9 of ‘Chapter 18 – Attachment Systems’ have been met, the LVV Certifier can approve this steering shaft.

I hope this helps, Justin

[dax]

Whew - most grateful. Yes I built the vehicle early '90's and used it in UK until bringing it home in 2002. I had visions of alternative steering colum setups, new wiring, new intermediate shafts and then the issue was simply moved to how to join to the rack! Many thanks.

I must say this forum is extremely helpful as is the HC Manual - a vastly easier process than it was in the UK way back then - I got caught in the period when SVC was being tested by the deskbound mandarins! Having built a few Dutton Phaetons (the poor man's answer to the Seven) way back prior to that when there was no compliance, it was a shambles for many years but NZ really does seem to have sorted it.

[Justin]

You're welcome, always happy to try and help!

Justin

[dax]

To go back to this issue, can anyone tell me what material is used for steering colums? In the longer-term, I may obtain a length and machine it to a triangle shape to slide inside the collapsable Sierra top/outer and then have a spline nachined onto the end, thus ending up with one solid section.

But, what is the material - someone has suggested unbatum which I suspect is a non-existent chemical !

[Justin]

Hi again

The Hobby Car Manual (7.11.1) says; a custom-manufactured steering intermediate shaft incorporated within a steering system in a low volume vehicle, must be manufactured from a high quality, easily-machinable material that is readily available.

In the sidebar, it suggests that SAE 4130 is an ideal material for this application.

I hope this helps.

Justin

[dax]

Ah once again a stupid and lazy writer who hadn't read the manual. My most profuse apologies Justin.

[Justin]

Not at all - there's a huge amount of info in there, and we're happy to help.

Don't hesitate to ask any questions.

Justin

[jcsh]

I have exactly the same setup! and also live in Nelson!
My car was built many years ago in UK. The inspector I spoke to recently seemed unaware of this historical exception capability so I am pleased to hear about its existence.
I'm unsure of the other regs that you refer to: "where the requirements of 18.9 of ‘Chapter 18 – Attachment Systems’ have been met." can you please tell me what they entail? or whether since its the same as Mr Dax above that it is irrelevant..?
Thanks very much
James

[Justin]

Hi guys

Chapter 18 of the Hobby Car Manual, section 18.9 spells out the requirements for a critical function weld. I suggest that you get your hands on a copy to make sure that these requirements can be met.

In a nutshell;

1) Must be TIG welded
2) Welds must not be ground or linished
2) Must be non destructively tested by an appropriately qualified person and shown to be free of defects.

I hope this helps

Cheers, Justin