Update:
With me deciding to move the radiator forwards I had to move the lower mounts too, these were properly rusty:
Sits nice:
Next up I decided to box in the top of the servo area, as i've installed a MK4 Astra servo which is bulkhead mounted this box section is needed. I started with the top curve:
I then added the back and welded it all up:
In the next picture I added the wiper setup, I thought as first a slight pivot up of the motor would get it to clear the box section and all is well:
Unfortunately the motor arm smacks the box section in big way so I had to relocate the motor several inches away:
I also flattened the motor arm and redesigned the first part of the linkage in order for everything to clear:
Also a slight trimming of the cabin fan housing was required:
I then welded in the new wiper bracket:
Final position has the motor very close to the box:
Next up was a big hurdle, the steering linkage. I knew it would need 3 universal joints so it was going to be a pig. The linkage first drops out of the bulkhead at a low angle to clear the servo:
I double checked the angles and distances of the Corsa-C EPAS column, in lowest position:
Highest:
I then reset the position of the rack which I messed up months ago, whilst doing that I stripped the boots off the rack and added a few spacers so it matched the original Carlton centre steering linkage distance exactly:
In this picture I have the original Carlton tie rod (below) and the Corsa-C (above), I need the length and thread of the corsa-C unit with the tapered part the size of the Carlton one. I'm thinking Astra/Vectra?!?!?
With the rack and column positions set the engine needed to go in to build around it, this is also the first fitment of the engine with it's gearbox fitted:
I am happy to find out the factory Carlton gearbox mount bolts straight up!
I also took this opportunity to check the corsa-d battery tray, it clears the engine perfectly!
New oil filter position is fine too:
Radiator is miles from it:
So this is what I have to work with: Shot from above you can see the manifold and on the left the cut up UJ:
A picture taken from inside the arch on the same side, these are the original holes from fuel lines and brake lines... safe to say I won't be using them with an exhaust pipe on the other side!
A few hours of swearing and I have a prototype 3-joint steering linkage, its fully adjustable too:
View from the top again shows the first part:
The cut out rust sections of the inner arch gives me some helpful views of the 2nd part of the linkage with the bearing:
It gets very close to the manifold:
I kept at it, using it's adjust ability to tweak it here and there, I managed to get the bearing to 10mm from the manifold and I guess it will have to be heat wrapped. I started cooking up a mount for the bearing but ran out of time... I did however manage to try out the steering and it works fine!
With me deciding to move the radiator forwards I had to move the lower mounts too, these were properly rusty:
Sits nice:
Next up I decided to box in the top of the servo area, as i've installed a MK4 Astra servo which is bulkhead mounted this box section is needed. I started with the top curve:
I then added the back and welded it all up:
In the next picture I added the wiper setup, I thought as first a slight pivot up of the motor would get it to clear the box section and all is well:
Unfortunately the motor arm smacks the box section in big way so I had to relocate the motor several inches away:
I also flattened the motor arm and redesigned the first part of the linkage in order for everything to clear:
Also a slight trimming of the cabin fan housing was required:
I then welded in the new wiper bracket:
Final position has the motor very close to the box:
Next up was a big hurdle, the steering linkage. I knew it would need 3 universal joints so it was going to be a pig. The linkage first drops out of the bulkhead at a low angle to clear the servo:
I double checked the angles and distances of the Corsa-C EPAS column, in lowest position:
Highest:
I then reset the position of the rack which I messed up months ago, whilst doing that I stripped the boots off the rack and added a few spacers so it matched the original Carlton centre steering linkage distance exactly:
In this picture I have the original Carlton tie rod (below) and the Corsa-C (above), I need the length and thread of the corsa-C unit with the tapered part the size of the Carlton one. I'm thinking Astra/Vectra?!?!?
With the rack and column positions set the engine needed to go in to build around it, this is also the first fitment of the engine with it's gearbox fitted:
I am happy to find out the factory Carlton gearbox mount bolts straight up!
I also took this opportunity to check the corsa-d battery tray, it clears the engine perfectly!
New oil filter position is fine too:
Radiator is miles from it:
So this is what I have to work with: Shot from above you can see the manifold and on the left the cut up UJ:
A picture taken from inside the arch on the same side, these are the original holes from fuel lines and brake lines... safe to say I won't be using them with an exhaust pipe on the other side!
A few hours of swearing and I have a prototype 3-joint steering linkage, its fully adjustable too:
View from the top again shows the first part:
The cut out rust sections of the inner arch gives me some helpful views of the 2nd part of the linkage with the bearing:
It gets very close to the manifold:
I kept at it, using it's adjust ability to tweak it here and there, I managed to get the bearing to 10mm from the manifold and I guess it will have to be heat wrapped. I started cooking up a mount for the bearing but ran out of time... I did however manage to try out the steering and it works fine!