Haynes Roadster Steering Rack

I had neglected to make a jig for the steering rack, but mounting it turned out to be very simple.

To do this job, I was armed with a height from the bottom of the chassis rail to the top of the central portion of the steering rack. I had taken this from my CAD drawings and calculations done some time ago.

I knew, after much measuring and re-measuring, my suspension pick-up points were well within a millimetre of my CAD. I therefore ignored these from the equation.

I had a brand new Ford MK II Escort “quick rack” bought at Stoneleigh Kit Car show last year. I cut the cable ties that secured the rubber boots in place and rolled them back out of the way. The ball joints of the steering rack arms and the central section of the rack were now exposed. I then turned the steering linkage to check what the full range of movement the the steering arms was. Conveniently, the arms moved until butting up to the body of the steering rack.

By measuring the length of the steering rack body and dividing this by two (633/2 = 316.5) I had the centre line of the rack. Using several right-angle squares, it was easy to line this centre line up with the centre-line I had scribed into my chassis. It was also easy to get it perpendicular to the chassis line.

All that was left to do was get it to the correct height and level it up. I did this with a height gauge and a digital spirit level. As a double check, before welding, I checked each end of the rack was at the same height (they were). I then tack welded it up, removed the rack and finished welding.

It was one of those jobs that you stand back from and think “That was too easy – What’s Wrong?”

Well OK, I might re-make one of the rack clamps as it isn’t possible to get it as tight as I’d like, but that is it.

I did have a lovely set of billet aluminium rack clamps, but these as for solidly mounting a steering rack and I have decided to use Polyurethane bushes. After all, although this is a sports car, it will be daily driven and I don’t intend to race it. – Hence the homemade 2.5mm steel belt plate. The rack clamps were carefully linished to prevent the clamps from wearing in use.

Haynes Roadster Steering Rack

Although it was a bit late, I crudely doubled checked that the steering rack ball joints lined up with the suspension pick-up points. I did this to check for bump steer (with the steering in the neutral position). The racks steering arm ball joint certainly lie on the intersection line of the two suspension points, but until I make the steering rack extensions and ream out the tapers on the uprights’ steering arms, I cannot check the intersection of lines at the Instantaneous Roll Centre (I.R.C.).

Bump Steer

In the photo above, you can see that the track rod end is fitted to the underside of the steering arm. I need to weld up, drill-out and re-ream the steering arms so that the track rod end mounts on top of this arm. I have some spare uprights and the Brother in Law found they TIG weld quite nicely without problem.

Steering Rack Universal Joint

In the above photo you can see a 14mm universal joint attached to the steering rack. This was one of those ‘It looks too cheap to be any good’ experiments. They were on Fleabay advertised as ’14 x 14mm Diameter Steering Universal Joint Motor Coupling Screw OD28 L60′ and came from Yueqing, China. The ones I had looked at in the U.K. were about £80 before delivery. These stainless ones were £12 including delivery and even cheaper if I bought several. It turns out they look pretty good quality and do the job perfectly. I’ll have to drill the rack to accept a split pin, but after I tapped it on with a mallet the splines on the rack gripped the U.J. so hard I’m going to struggle to get it off. The split pin would be just a back-up fail safe.

Custom Sierra 4x4 Uprights Part 2

A while back, I'd bought some super light weight billet Outlaw aluminium callipers (Wilwood copies). At the time I didn't have the front discs to check them against so they were just put under the bench. When the Granada 278mm front discs arrived, I soon saw that these callipers were ...

Haynes Roadster Steering Rack Part 2

I wasn't at all happy with my steering. Because this car is 4x4, the rack was pushed nearly 2" further forward than on a standard Haynes Roadster / Locost. The steering arms were angled backwards about 5 degrees. It didn't look good. Ideally, the steering arms should be in-line with the steering arms / ...

Haynes Roadster Steering Shaft

The steering wheel is finally connected to the front wheels. I've used 4off 14x14mm stainless steel universal joints imported from China (OD28 L60). They are available for around £14 if you check the auction sites. They take a while to turn up but they seem just as good as ones ...

Steering Rack Extensions

What size steering rack extension do I need for a MKII Escort Steering rack and Sierra Cosworth 4x4 drive-train? Steering rack extensions were likely to be a different length to those in the book, because I'm running four wheel drive. I'm using a Ford MKII Escort 'quick rack' and Ford ...

Corsa EPAS Power Steering - Kit Car

For all those fitting a Vauxhall Corsa C EPAS (Electronic Power Assisted Steering) to a Kit Car or Hot Rod the following should be helpful. It seems a very popular subject, as around a 30,000 people per month read my EPAS posts, yet the quality of information on other popular forums ...

Corsa C EPAS speed controller

Corsa C EPAS WiringHave you ever wondered what the correct inputs to the Vauxhall Corsa EPAS column should be? The column requires 12v, an rpm signal and a speed signal. But what frequencies? I've been trying to get my Vauxhall Corsa C EPAS steering column to work correctly. From my previous blog article ...

Custom Ford Sierra Front Uprights

I had to enrol the skills of the 'brother in law' to TIG weld the new Ford Sierra based front uprights. He's done a cracking job :) The upright has the same bolt spacing for the Mercedes S320 Brembo calipers as the removable steering arm assembly. Therefore uprights can be swapped ...

Escort MK2 Steering Rack

It's not obvious from this drawing but a standard Ford Escort MK2 steering rack is not ideal. The rack needs to be mounted where it clears the front Cosworth 4x4 diff. In this case a long way forward. The steering arms on the custom uprights would be nearly 30% longer than ...


Ford Sierra - Sectioned IRS DWG CAD
Front Suspension Sierra - DWG CAD
Front Suspension Cortina - DWG CAD
Ford Escort MK2 Ball Joints - DXF CAD
Ford Escort MK2 Steering Rack - (Left Hand Drive) - dxf
Ford Escort MK2 Steering Rack - (Left Hand Drive) - DWG CAD
Translate »

Web Design by Go Web Solutions