Modification Of Mk2
Steering Wheel To A Different Column
by Robert Ashworth
As part of the
mods I am doing to my Mk2 Consul I have fitted a steering column from a
Fairlane, in order to give a column change for the autobox on the back of the
Rover V8.
The Fairlane
column had come to me without a steering wheel however, so I need to find
something I could use. In any case, I really wanted to keep the standard Consul
steering wheel as this car is intended to be a "sleeper" with no
major bodywork or interior mods to hint at the V8 under the bonnet.
Of course, the
diameter & spline pattern of the Consul wheel was not the same - that would
have been just too easy! I knew I could modify the Consul wheel centre to
accept a different boss, if only I could find something that fitted from which
to cut the centre. After some fruitless searching, the answer had been sitting
in the garage right in front of me all the time – Mk2 Escort.
I found a scrap
steering wheel from an Escort and roughly cut the boss from this. I then
carefully attacked the Consul wheel to remove as little plastic as possible
from around the boss to investigate its construction. I found out that there is
a metal strengthening rod encapsulated within the spokes of the wheel, which is
welded to the large "nut" that is the splined centre boss. Using a
thin cutting disc in my grinder (a deliberately worn disc, so that it was as
small as possible in diameter), I was able to cut through these welds to
release the centre boss.
I then had a
loose centre boss (from the Escort) which fitted the Fairlane column, and the
hexagonal boss from the Consul wheel. I needed to somehow create one from the
two having the "inside" of the Escort boss (to fit the column) and
the outside of the Consul one (to fit the wheel). Luckily, my father-in-law is
an experienced model engineer and has a home workshop with metal shapers,
pillar drills, and lathes…. contrary to rumour I only found this out after
I’d met his daughter! He kindly offered to bore out the centre of the Consul
boss and turn down the Escort one to fit within it. We then had these TIG
welded together and, after checking back on the column to determine the
absolute position, this was TIG welded back into the wheel. The plastic
surrounding this weld survived well, and from the "outside" (what’s
visible when it’s fitted to the car) there is no evidence of the mods.
Early on I’d
resolved that I would have to abandon the horn function of the trim ring in the
centre of the wheel, but I will be refitting the trim ring solidly mounted to
preserve the look. I’ll be fitting a Capri stalk assembly (suitably disguised)
to the column as this will give indicators, horn, and a means of flashing the
main-beam headlights all in one.
I also need to
improvise some sort of locking tab washer for the retaining nut, shouldn’t be
impossible.
Hope this helps
someone… maybe wanting to do the opposite and fit a non-standard wheel to a
standard column. Anyone who would like any more information or pictures, please
email.
Robert Ashworth
August 2007
Disclaimer:
The advice and guidelines given in these articles are given in good faith.
The owners and managers of the Galeforce Zephyr site will take no
responsibility for any injuries or loss sustained while carrying out the
described tasks and procedures or any consequences arising. Please read
the Safety
First Article