power steer is now finished :) new pix added

[christover1]

My power steer conversion is finaly underway, now I'm at last feeling a lot better. Decided on a full vit set-up, to avoid any clashes.
A big thanks to Joey for his welding, drilling and grinding of the box mounts for me today, Sunday (sr20 joey)
Thanx Beck for lending him to me
Beats the heck out of hand drills, files, and superglue.
Vit pump needs to be mounted higher than I thought, due to chassis clearance and rad mounts. So use of original mounts on motor is a no go.
A bit of 8mm plate and pump mounting will be finished.
Should be able to use a standard belt, still, but not a drama.
Steering box was mounted flat to chassis, as any straightening of, or conversion plates would have left me no room.
We plated the outside of the chassis, as there wasn't enough metal left after removal of original centre mounting sleeve.
My rad mounts will have to be modded slightly, probably because 1.0 to 1.3 conversion is a little different to stock 1.3's engine bays.
Well at last we have stopped talking and started spinning spanners

christover

[christover1]

PS, we used one of the original mounting holes, so we feel more secure ...
in both the pump and the box.

[christover1]

tomorrow finish the pump mount and paint the new welds etc.
then mount box and do more thinkin
I'll get some better shots when I can get it outside, in the sunshine...light gets swallowed by my shed, like in a black hole...

christover

[sierrajim]

Looks tops chris. Might be time to weld that front diff and do a DIY "how to weld a diff on a Zook"

[mugginsmoo]

nice work


can't wait to see it in action

Mitch

[christover1]

Looks tops chris. Might be time to weld that front diff and do a DIY "how to weld a diff on a Zook"

I put a welded centre back in, thats what inspired the power steer, but I didn't weld it, just fitted it. I really missed the welded front.
It's 1 of joey's old already welded centres.
I think there is a welding diff thread somewhere, I remember uploading a pic to it...
christover

[christover1]

Well today I moved the pump down a tad.
As simple as elongating the bottom hole instead of the top one, in the original mount.
Did this so that an original vit power steer belt can be used (non a/c), simpler for maintainance, spares and shopping.
I've used the top mounting hole on the block with the lower hole on the pump mount, theory being it should line up ok. the top mount is in a hole I suspect is for a a/c? An 8mm spacer was needed here, and this also doubles as twist stopper (cant use the 6mm bolt of original as I moved it up. To my eye its a tiny bit out of line, about the same as the alt is out of line, so may just drill slightly larger holes, tommorrow, so can slide it out more in line with harmonic pulley....may not, too
Interesting note, G16A vits have a different part number/lengths to G16B.
I chose the longer as it was cheaper, lucky guess, was exactly right.
30mm longer, they maybe changed pulley sizes or something???
more pix when sunlight allows.

christover

[largesuzy]

the how to weld a diff thread in the bible

[christover1]

nothing exciting, today. Painted/cleaned all the new brackets and chassis work....altho paint is now dry enough, it's too darn dark and cold in the shed, so have called it quits early.....paint will be stronger after a nights drying anyway

christover

[christover1]

some explanatory pix

[christover1]

another

[christover1]

Almost finished.
Thanks to Joey for another weld job on the new rad mount.
Got to remount the radiator overflow bottle, as the ps lines got in the way.
Got to paint the bracket for the reservoir and the overflow bottle.
Got to tie down the lines and refit bullbar and mesh.
Then I just need to get hold of a collapsible Sierra steering shaft (as I don't really want to try to shorten mine.)
Ran the engine, no problems seen or heard yet good sign.
grabbed the input to the steering box, and I could get the wheels to turn slightly ...so I'm guessing it works, and will be nice when actually connected to the steering wheel.
All's going well, albeit slowly.

christover

[christover1]

Now I'm watching paint dry again
But tomorrow I finish fitting reservoir and overflow bottle.
The ps lines need tying down and fitting round thingz, need to fit a new longer hose to overflow bottle.
And then chase up a steering shaft and we will be done...I think.
Photos will come when I get it outa shed.
christover

[christover1]

All done, except the steering shaft
Off to Suziworld to hopefully get a shaft tomorrow, as opposed to getting the shaft
Now to tidy up a lot of mess n tools all over shed.
Can't wait fer a test drive.

christover

[christover1]

I got me collapsible steering shaft from suziworld.
Just having a little trouble convincing it to collapse.
Must be years of dirt and rust.
Drilled out the little nylon plugs, I am now soaking it boiling water, to try to loosen it. Have sanded off the paint a little, see how we go.
This was supposed to be the easy bit :(
christover

[christover1]

Now I know for sure,
I'm soft
Power steering rox
Wanted a quick check down driveway, but couldn't make myself stop, and kept driving fer a couple of hours. No magor probs, just a bent radiator bracket catching on the pitman/draglink bolt. A bfg bang, bang, fixed.
Only done road testing, close to home, till I trust I've done everything.
Need to do a safety check, bleed, change water to coolant, but basically finished
Big thanks to my folks for helping with the finances, and to Joey for his welding help. And thanks to Beck for letting me have him.
Thanks also to all the club and forum members for advice and encouragement.
Thanks to James for a good deal on the bits.
Photos will come soon, ran out of daylight, to busy playing.

christover

[alien]

this sounds unreal =)

Be great to see how it goes offroad! no more wrenching the steering wheel on rocks! hopefully it eliminates bump steer too (if you hadnt already) - power steering with bump steer would be scary! haha

[christover1]

this sounds unreal =)

Be great to see how it goes offroad! no more wrenching the steering wheel on rocks! hopefully it eliminates bump steer too (if you hadnt already) - power steering with bump steer would be scary! haha

Haven't fitted the steering damper, will see if I need it. I did need it before, but only to eliminate the low speed death wobbles....I'm told I may not need a damper with power steer, but we will decide later..so far no death wobbles, tho I can feel it a bit twitchy where it would have occured before...or I'm just nervous
Bumps shouldn't rip steering wheel out my hands anymore, but steering wheel still changes position slighty when accelerating or decelerating.
Its still a zook with lift soft springs and stoopid wheel offset
christover

[norwestzook]

Hey Christover1, Great Job. Did you use the full Vitara setup?does the Pitman arm just bolt up or were mods nessary?
Cheers

[christover1]

Hey Christover1, Great Job. Did you use the full Vitara setup?does the Pitman arm just bolt up or were mods nessary?
Cheers

Thanks, been on the need list for a while
All full Vitara setup.
Pitman arm is Vitara, it just bolted to the Sierra drag link.
Lines needed a bit of massaging to fit the Sierra, this would be better with a proper pipe bender thing, or even better new lines.. But I'm cheap
More pix this arvo, if day goes as planned.
christover

[christover1]

Box sits at this angle when flush mounted, some choose to make an angle plate and straighten it up...I took this route for ease of job.

Needed to bend a bit of panel out of way of the ps lines, no real drama

Need to mount box so as to allow clearance of the pitman/draglink bolt to clear chassis rail...its very tight fit.

[christover1]

Raising the pump up to clear chassis rail made the need for the 8mm spacer, easier to see in this shot. Original mounting has a 90 degree bolt as well, to prevent twisting..I extended the spacer to back bolt hole and front of mount to help prevent twist.

Rag joint at the firewall end, this gave me more room at box end, and also put less bend into rag joint..I don't know if this is possible with power assisted 1.3 setups???

[christover1]

reservoir mounted here keeps it roughly same height as it was in the vitara. They are mounted on the top of radiator mount originally. Thought height may be important for correct function?

Got hold of a later model collapsible steering shaft, drilled out the nylon plugs, then slid it in to shorten shaft. They are designed to collapse in a crash, I guess. You probably could have one made up.

With the uni joint at the box end, there was more room than with the rag joint there.....also uni joint can handle the sharp angle better than the rag joint can.

[HRZOOK]

Real nice and sweet tech

but how well does it work?

steer better onroad?

thanks
HR

[christover1]

Real nice and sweet tech

but how well does it work?

steer better onroad?

thanks
HR

I just got back from the test drive.
Much better.
It doesn't wander so much (tho I think my standard box was stuffed)
The wind and road camber changes are not so daunting.
One hand can stay in pocket
Parking and especially reverse turning is real easy now.
Steering wheel feels too big, now.
I locked the front hubs on a dirt road, with front welded diff, and I was able to negotiate normal turning easily, and U turns well enough. I happy.
I still think I will need to keep the larger wheel for off road.
Have not needed the steering stabilizer yet, tho I may refit it later.
Need a proper off road test, now, but gotta wait till pay day (bloody petrols getting $ouch)
The slightly shorter vitara pitman arm has lowered the steering ratio a tad, so I need to retrain my habit driving.
My crook shoulders are going to be much happier, now

christover

[DiddyZook]

Chris

Good job. This thread needs to be moved to the Sierra Bible so that it will be easily referred to in future as more and more of us get old and soft Afterall most cars nowadays have poersteering standard so there is a whole generation who are learning to drive with it and then thinking there is something wrong when they get into a Sierra and have to turn the wheel themselves.

I know you are not one to throw money at a project, but if you don't mind me asking can you give an indication of cost. (obviously 2nd parts vary across the country but an indication of $$$, time and effort would be helpful for those considering this mod)

[christover1]

Chris
I know you are not one to throw money at a project, but if you don't mind me asking can you give an indication of cost. (obviously 2nd parts vary across the country but an indication of $$$, time and effort would be helpful for those considering this mod)

originally I was quoted $440 for entire vit set up from suziworld, which is about industry norm from what I can tell.
But James had a set for $300.
Steering shaft cost me $20, tho this would probably cost more for non suziworld regulars.
Metal pieces were free from the offcuts section of rp steel
About $20 in paint and sundries.
$14 for a new pump belt (non ac type)
Welding was done free by my mate Joey.
I guess welding supplies aint cheap?
Using a toyota box would be cheaper, but I found them getting old and rarer, and also I preferred matching parts, to avoid any unexpected probs. (mum & dad kicked in with dollars as a nice surprise)
I took about 2 weeks, but this is not a good indication, as I ve been ill, and doing job very slowly, bit at a time, letting paint dry etc. Also most people only have weekends or nights free.
It would certainly be easier in a zook that was a standard 1.3, as my only real issues were with my own 1.0 to 1.3 mods getting in the way.

christover

[christover1]

After a quite a few Off Road excursions, I would say this is the greatest thing I've done to the zook for a while. The combination of welded front diff and power steer is brilliant. For my needs/budget I don't feel a proper locker, air or auto, is of any benefit to me.
I can drive it ok on all dirt without unlocking a hub.
Though if I know its a long trip, I unlock hubs.
I don't need to unlock hubs, altho it may be easier, even on u turns.
Also have not fitted the steering stabiliser, yet, but doesn't seem to need it. The vit don't use them, but they don't have the sierra beam axle.
On road benefits were greater than expected, and I have not lost road feel, as some p/s can do.

christover

[1Lzook]

i have just finished putting pwr steer onto my sierra, yet to drive it but have u found the need for a steering damper yet ?

[christover1]

i have just finished putting pwr steer onto my sierra, yet to drive it but have u found the need for a steering damper yet ?

No mate, it's still sitting in a drawer in the garage.
Will probably sell it, as its not very old and is arb/ome one.

It may ease the stress on steering or some other purpose that I don't know of, but I have not missed it while driving on or offroad.
I doubt I'll ever put it back on.

You will love the steering.

christover