Jet Jockey/A4 Pilot

First I would like to thank Ben and Marc at <b>AUTOSPORT SERVICES</b> for their work. Ben is also the technical rep for <b>ECUTEK</b> North America. As such he travels the whole world to train new technicians and program Subaru STIs and EVOs with Ecutek's proprietary software. Also part of the project was Ioan and Joel from <b>TEHCNOART COMPOSITE</b>. They specialize in Carbon Fibre, Fiberglass, and any metal and make basically anything from scratch in their machine shop. Their specialty is prototyping a project from it's beginning on the drawing boards to its completion.

OK because I backed up my Recaro race seat as far back as I can in the car (right up against the roll cage) my OE steering wheel/column was not long enough even in its fullest extended position. Besides I wanted a race steering wheel with a quick release to be able to get in and out easier.

First part of the project was to disassemble the OE steering wheel, the control column and the two shafts that link everything together. As you will see this stuff is heavy and as a bonus I was hoping to shed some weight and we did between 5 and 6 pounds when all was done.


Once all the padding and cosmetics are removed this is what is revealed. You can see the ignition harness the whole mechanism to adjust the steering column and at the back you see to shafts with two universal joints. The whole thing is held in place by four 6mm bolts (two seen here).

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-Controlcolumn-.jpg">


In this picture we see the shaft just before the inner firewall. Notice the "collapsible" mechanism in case of an accident.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-Controlcolu-1.jpg">


Once the adjustable steering column mechanism is removed you are left with the two shafts.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-Controlcolu-2.jpg">


Here the two shafts are removed from the car and are about to be cut apart.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-Controlcolu-3.jpg">


The shafts were then secured on the bench saw to be separated at the proper location. We did not need the portion or smaller shaft but we wanted to keep the "collapsible" portion.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-Controlcolu-4.jpg">


After the cutting...

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-Controlcolu-5.jpg">


Here's the mechanism for the adjustable steering column once removed (no light weight). This is the top view.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-Controlcolu-6.jpg">


Another angle showing the bottom side.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-Controlcolu-7.jpg">


Here's the OE aluminium casting assembly that secures the whole thing to the car. We wanted to use it at first but it would have been too complicated to remove the inner guts. So we decided to make our own by copying it.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-Controlcolu-8.jpg">


Here's the initial design of our plate to secure the new steering wheel assembly in place. More holes would be punched out to lighten it and two reinforcement brackets would be welded to the final design to increase its rigidity torsionally. It's made of a ¼ inch thick aluminium plate.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-Controlcolu-9.jpg">


So now we need to replace the OE shaft or column that was cut off and measure a new one to the proper length for my seating position. We decide to go with ¾ inch steel tubing.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-Controlcolu-10.jpg">


To secure the new column we went with this type of bearings, two of them that would be mounted to the new plate in this fashion.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-Controlcolu-11.jpg">


Close up of the ¾ inch steel tubing with the bearing installed.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-Controlcolu-12.jpg">


The bearing housing is aluminium with a brass insert covered by a stiff rubber ring impregnated with grease. This provides maintenance free operation.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-Controlcolu-13.jpg">


Here's the female part of the SPA quick release. The other end bolts onto the steering wheel.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-Controlcolu-14.jpg">


Here's its male counterpart. The shaft is actually bigger than our ¾ inch steel tubing. It will be welded to our new steering column shaft/tubing.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-Controlcolu-15.jpg">


After the welding and machining to the steel tubing.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-Controlcolu-16.jpg">


Before we go onto the other step which is the connection of the new tubing to the OE collapsible shaft we need to look how the OE shafts were press fit into the universal joint. The end that will be removed is just below the green mark.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-Controlcolu-17.jpg">


So the other end of our new shaft was secured in a milling machine to get some custom shaving. LOL.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-Controlcolu-18.jpg">


Just enough steel matter removed to press fit it into the universal joint.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-Controlcolu-19.jpg">


Here the new shaft is joined to the universal joint by press fitting it into place.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-Controlcolu-20.jpg">


Reverse angle or the other side of the shaft/universal joint.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-Controlcolu-21.jpg">


To be safe of course the outer side was also welded to prevent the shaft from coming out. The two bearings at this point have already been installed onto the shaft.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-Controlcolu-22.jpg">


Assembling the new shaft and OE collapsible shaft to the new aluminium plate. Shown here is the top side of the plate. The bearings and shaft are on the bottom side of the installation. As you can see more holes were punched out to reduce its weight.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-Controlcolu-23.jpg">


Here's the other side or bottom side.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-Controlcolu-24.jpg">


Here's close up showing the bearings and the stiffening bars.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-Controlcolu-25.jpg">


Here it is once installed in the car.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-Controlcolu-26.jpg">


Another angle.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-ControlColu-27.jpg">


Finally the OMP steering wheel. It's 350mm wide or 25mm smaller than the OE steering wheel (375 mm). It also as a moderate dish to it.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-ControlColu-28.jpg">

Reverse side showing the SPA quick release mated to the steering wheel.

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-ControlColu-29.jpg">


Here it is finally installed in the car. The horn will be wired in with its own quick release at a later date (after the interior paint job).

<img src="http://i17.photobucket.com/albums/b79/mlab601/CAR-OMPSteeringWheel-ControlColu-30.jpg">