DRIVER’S Diary

This month, I’ve been mainly working on steering...

Recently, I have managed to put in quite a few hours on the Davrian. As was highlighted in my previous diary report, I’d been working on the steering, having discovered quite a significant crack in the steering rack mounting plate. Graham Anderson supplied me with a rather spiffing powder-coated replacement, and as mentioned previously, I overhauled the steering rack, fitted a new gaiter and fitted a new bush to one of the trackrods.

Well, a few weeks ago I knuckled down and refitted everything. The first step in this process was to attach the rack mounting plate, complete with its U-bolts (these locate and help hold the steering rack in place). However, this time around I wanted to ensure that the mounting plate was as rigid as possible. The bolts that secure the mounting plate in place used to simply pass through the fibreglass bodywork, with washers helping spread the load. Whilst this arrangement sufficed, I felt it could be improved. So, in place of the washers I’ve fitted two strips of 4mm thick steel. These span the entire width of the mounting plate. They really beef up the structure and should ensure that the mounting plate is not only better located, but also that it’s not going to crack.

The steering rack was the next item to be fitted, and I managed this without too much hassle, although since I’d pre-fitted the track rods, there was quite a bit of manoeuvring involved. The same was true of the wishbones, as they are not only heavy (thanks to the stub axle/brake assemblies still being attached), but there’s not much room in which to work. Nonetheless, eventually the wishbones slotted in, the bolts slid home and I was able to nip up the nuts. Then it was a matter of reattaching the shock absorbers, the check straps and the track rod ends. New bolts, nuts and washers were used throughout. Following this, I tightened every nut, checking and rechecking.

I’d like to report that the newly-refurbished steering operated seamlessly right away. Unfortunately, as I turned the steering wheel to check if everything was OK, I could feel something catching. Upon investigation, it turned out that the UJ which connects the steering column to the steering rack was making contact with the rack mounting plate.

Although the old and new mounting plates looked identical, the slight variations that come about due to manufacturing tolerances meant that the hole which the UJ passes through in the replacement mounting plate was ever so slightly offset compared with the original one. The only solution was to enlarge the hole. Thankfully, there’s plenty of metal in this area. I unbolted the column, detached the UJ and used a rotary tool to relieve the opening and gain the necessary clearance. The column and UJ were then reattached and I was delighted to discover that there is ample clearance and nothing makes contact. I’m now looking forward to getting the Davrian out on the road and seeing how the refurbished steering performs.

Although the Davrian hasn’t been out on the road, the Porsche has, clocking up lots of miles going to shows. It’s done the Abergavenny Steam Fair, the Golden Valley Vintage and Country Fair, the Blaenavon Heritage