Steering Wheel Hub

The supplied steering wheel hub is designed to fit a Vauxhall Vectra column.  I have used a Vauxhall Corsa C column which has different splines.  The Corsa is a larger diameter so my hub needs to be drilled out and new splines added to match the column.

I wondered how best to try to create these splines, and I asked a friend who is an excellent machinist how to do it and he said he will sort it!

I had a spare column and steering wheel which I gave to him so he could modify the hub to fit.

He drilled out the hole to the correct size ready to be able to accept new splines.  He counted the number of splines required and marked his lathe so he could rotate the chuck to the exact rotational position.

Using a cutter, he used his cross slide to cut a new spline at each of his marks.  This was done until he was all the way around.

Once all machined (a recess had to be cut into the forward end), the hub fits perfectly onto the Corsa column.  It does use a thick washer under the bolt head to compensate for the different depth.

I then added in the indicator automatic cancelling by drilling 2x 6mm holes and bonding in some short stainless tubes in a similar position to the original Corsa wheel.  The steering wheel was then bolted on - threadlock added to the set screws.

Door Handle Protector

When I fitted the door handles, I was aware that they rubbed on the leather of the door card.  Eventually this will cause wear on the leather.  I was always on the lookout for something that could be used to protect this without looking unsightly.

I came across 2 small plastic tubes, one end with a smaller diameter hole.  They even have a recess for the leather.  Not sure what these are from, but they fit perfectly! 

This will prevent the leather from deteriorating by the door handle rubbing on it.

Radiator Stone Protector

I thought I had better create a protection screen for the aluminium radiator since it probably won't take too many stones to puncture it.  I removed the number plate bar for better access, and created a frame using 16mm aluminium angle.  Once the frame was created, a friend TIG welded the corners.

The frame is bolted up through the aluminium underbody protector into rivnuts, and also fitted to the top radiator mounting frame.  I fitted stainless mech which has 5mm openings, hopefully will stop most stones without affeting too much airflow.  The mesh was bonded into the frame using CT-1.

Wipers

I re-checked the wiper park before fitting the blades - the wipers wipe the wrong way!

For this you need to take out the wiper motor, and swap over the inside mechanism to the other side.  Not too difficult, just a bit of a pain.  While disconnecting the plug I thought it felt a little loose so I also closed the terminals a bit so they fully gripped their opposite in the wiper socket.

Once the mechanism was swapped, the wiper blades were installed.  Job done.