Magnasteer Variable Rack Install Completion
Magnasteer Variable Power Rack
First let me say that I could not have added this rack to my build without Mike (MikePMS). He fabricated the brackets for the rack and modified the kit's alternator bracket to house the alternator and donor power steering pump. He also has years of knowledge and lots of knowhow with aircraft systems which have proven valuable for out GTM builds. Thanks Mike.
I modified the reservoir’s original bracket and mounted the reservoir with a set of rivnuts, button head bolts and lock washers. I mounted the aftermarket cooler after hitting it with the black radiator paint, to the front side of the condenser directly below the driver’s side fan. I used 3/8" hard line through the tunnel and 3/8" hydraulic fluid lines. The high pressure side connections were made using the hydraulic fittings that were attached to the two high pressure hoses I had modified. I tested the system and still need to secure all of the lines to finalize the install. I'm eager to take it for a test drive.
An additional major plus to the addition of this rack is that we have effectively taken the bump-steer down to almost zero. The manual "mustang rack" adds bump-steer. Factory Five sells a kit to improve (decrease) the bump-steer, but it cannot zero it through the full suspension travel. By testing the donor rack at different heights and angles we were able to effect a near zero bump-steer through the entire travel of the suspension.
I modified the reservoir’s original bracket and mounted the reservoir with a set of rivnuts, button head bolts and lock washers. I mounted the aftermarket cooler after hitting it with the black radiator paint, to the front side of the condenser directly below the driver’s side fan. I used 3/8" hard line through the tunnel and 3/8" hydraulic fluid lines. The high pressure side connections were made using the hydraulic fittings that were attached to the two high pressure hoses I had modified. I tested the system and still need to secure all of the lines to finalize the install. I'm eager to take it for a test drive.
An additional major plus to the addition of this rack is that we have effectively taken the bump-steer down to almost zero. The manual "mustang rack" adds bump-steer. Factory Five sells a kit to improve (decrease) the bump-steer, but it cannot zero it through the full suspension travel. By testing the donor rack at different heights and angles we were able to effect a near zero bump-steer through the entire travel of the suspension.
Magnasteer Varable Power Rack Install
More progress on the rack install. In order to zero the bump-steer input of the wider Magnasteer rack the tie rods need to be mounted from above the spindle. Off road vehicle projects use this technique to get more clearance and add a much more durable and reliable steering system. The off road standard is 5/8" so that's what is used. Likely more than what is required here, but it will be solid and extremely durable.
I reamed the spindles for the 5/8" heim joints and 5/8" bolt. I installed the parts and it will get a fine adjustment during my alignment.
I reamed the spindles for the 5/8" heim joints and 5/8" bolt. I installed the parts and it will get a fine adjustment during my alignment.
Magnasteer Variable-Effort Power Steering Rack Install
I installed the Magnasteer Variable-Assist Power Steering Rack. In order to make room for the rack and access for the install I removed the windshield washer bottle. I plan to relocate it to the opposite side with the lid protruding through the hole in the wiper motor panel. The aluminum panel between the radiator and rack was removed earlier for the anti-sway bar install. I removed the EBTCM and it's mount. I removed the manual rack and steering linkage.
C5 Corvette Magnsteer Variable Rate Power Steering(PS)
I have been working with Mike on the rack. This is something I wanted to do initially, but did not because I did not have the tools required to make the modifications. I am waiting on a few parts that will arrive today and early next week. I am planning the install next week end. test the bump-steer. Mike has the required items and we have (most of the credit goes to Mike as he fabricated all of the mounts and required items for the modification.
There are two reasons why the kid does not use the C5 steering rack. The first is that FFR did not design a power steering pump into the kit. The second, and the primary one, is that the track on the GTM is about 3" shorter that the C5 corvette's track. This would create bump steer numbers that would be unexceptionable.
So how did we do it? Well, we needed a power steering pump to supply the hydraulic pressure and we need to zero the bump-steer.
We had the option of using the MR2 Spyder El Steering Pump which many of the GTM builders are using in combination with a power mustang rack. This is the easiest route to adding PS to the GTM because the rack bolts right in and only needs extenders. The spyder ps pump is well engineered and works OK with the mustang rack. One of the forum members designed a circuit to transfer the abs reluctor wheel signal to a Pulse Width Modulated signal that works with the spyder pump. This give the rack a variable rate relative to the speed of the GTM. Some of the drawbacks of this system are; cost, and performance.The setup cost just over$1000 for the lower-end mustang rack and about $200 more for the better rack. The performance of the system, if adjusted well, is great for normal driving, however the steering wheel will likely catch if you have to move it quickly when the pump is not already pumping at high speed.
Be Frugal as I am, Mike added a bracket to the kits alternator bracket to mount the donor's SP pump. In order to get the magnasteer rack bump-steer to zero. we raised the rack and made a bump-steer kit to fine tune the ajustments. Raising the rack allowed us to put the pivot of the racks rod end in line with the upper and lower control are pivots.
Mike has the system installed now and I am planning to install it next week end because I am waiting on a few parts to arrive that will be here today and early next week.
I sent Mike some items to modifiy and have re-worked. The first picture are the items before he packed them up and shipped them to me. The second and thrid are my magnasteer rack.
There are two reasons why the kid does not use the C5 steering rack. The first is that FFR did not design a power steering pump into the kit. The second, and the primary one, is that the track on the GTM is about 3" shorter that the C5 corvette's track. This would create bump steer numbers that would be unexceptionable.
So how did we do it? Well, we needed a power steering pump to supply the hydraulic pressure and we need to zero the bump-steer.
We had the option of using the MR2 Spyder El Steering Pump which many of the GTM builders are using in combination with a power mustang rack. This is the easiest route to adding PS to the GTM because the rack bolts right in and only needs extenders. The spyder ps pump is well engineered and works OK with the mustang rack. One of the forum members designed a circuit to transfer the abs reluctor wheel signal to a Pulse Width Modulated signal that works with the spyder pump. This give the rack a variable rate relative to the speed of the GTM. Some of the drawbacks of this system are; cost, and performance.The setup cost just over$1000 for the lower-end mustang rack and about $200 more for the better rack. The performance of the system, if adjusted well, is great for normal driving, however the steering wheel will likely catch if you have to move it quickly when the pump is not already pumping at high speed.
Be Frugal as I am, Mike added a bracket to the kits alternator bracket to mount the donor's SP pump. In order to get the magnasteer rack bump-steer to zero. we raised the rack and made a bump-steer kit to fine tune the ajustments. Raising the rack allowed us to put the pivot of the racks rod end in line with the upper and lower control are pivots.
Mike has the system installed now and I am planning to install it next week end because I am waiting on a few parts to arrive that will be here today and early next week.
I sent Mike some items to modifiy and have re-worked. The first picture are the items before he packed them up and shipped them to me. The second and thrid are my magnasteer rack.
Magnasteer Rack Install Started
The parts. The rack mounts and the alternator/PS pump bracket are custom fabricated parts. The rack mounts use the position the rack at the correct height and angle. The alternator/PS pump bracket was fabricated using an unfinished kit alternator bracket and an additional aluminum pulley sleeve from FFR. Two stock C5 high pressure PS lines were fitted with high pressure hydraulic ends that will accept the 3/8" line. The bump-steer kit was created with 5/8”, 17,000lb radial static load heims, and the kits rod ends.
I am also adding a PS cooler to match the ZO6 set up. The base C5 models used a length of 3/8” line along the rack as the cooler.
I am also adding a PS cooler to match the ZO6 set up. The base C5 models used a length of 3/8” line along the rack as the cooler.
Tie Rod Ends
The steering rack and tie rod combination as they are are longer than needed. There are two options for the steering rack to tie rods. Cut the threaded rods or tap the tie rods. I purchased the tap with plans to tap the rod. I chose to go the easier route and cut the rods. The rack is 3.3 turns end to end. I have read the of guys cutting 3/4" from each side. With the rack centered the passenger side needs less rod removed than the driver's side. I used the frame to make some measurements. my goal is to get about 1/8" of toe in with room for adjustment during alignment. So for now I removed 3/4" for the passenger side and 1,3/4 for the drivers side. I also proceeded to install the grease fittings on the tie rods. The fitting was installed in a 90 degree fitting. After breaking the one off on the passenger side I decided to remove the 90 and install it directly int the tie rod on the drivers side. I need to get a removal tool to pull the broken piece so I can install the fitting on the passenger side.
Telescoping Steering Column
The Column is being modified the way that Shane does for Tele Columns with the exception of keeping the Steering sensor. The manual is followed for the internal modifications after that the shaft is cut flush with the inner tube and the bearing portion of the sensor is used just inside the cut-off to support and keep the shaft. A section is cut from the upper portion adjacent to the telescoping bracket for frame clearance. The column is connected to the steering shaft with a flaming river UV joint. This technique does not require FFR telescoping column kit, is less complicated and alleviates the potential for the shaft linkage moving laterally. I have completed the internal mods and shortened the column.
Installed the steering column with the wheel position sensor. The tan portion of the sensor casing was discarded because in the new position it was under tension. I added a 1" Shaft Collar to keep the sensor in place. I replaced the column bolts with 2" bolts and added 1" of washers as spacers. I placed a thin piece of aluminum over and around the column where I removed material for frame clearance. I also added three rows of rubber weather stripping to the frame where the column contacts. The motor was installed as per the manual.
The next step is to add a secondary mount/support to the column to alleviate a potential issue. The issue is a shake in the column after hitting a bump or pot hole. Other builders has solved the issue by adding a secondary support between the column and the frame.
The next step is to add a secondary mount/support to the column to alleviate a potential issue. The issue is a shake in the column after hitting a bump or pot hole. Other builders has solved the issue by adding a secondary support between the column and the frame.
Steering Rack
Very uneventful. I installed per the manual.