40 years in the making...

[GoldHawg]

I installed the new electric power steering unit from Zpowersteering.com. This was not quite "plug and play", even though it was for a roadster. I ended up making a new plate that holds the firewall bearing, and I had to cut the larger portion of the double D shaft that connects to the EPS unit under the dash (I ended up taking about 3/4" total in two cuts to get it to fit). I also had to cut the steering shaft down, then put it in my lathe to turn it down to fit in the splined section of the u--joint connecting to the engine side Double-D, and then tig weld it together. I shudder to think how I would ever get it out if needed (whole EPS would have to come out, so dash would too). I also had to cut off the brake pedal light switch and installed an inline pressure activated switch (but that turned out pretty clean), and relocate the pedal return spring. And since I also did the firewall brace mod, of course it doesn't work with the firewall plate/bearing for the EPS, so it had to be hacked quite a bit to fit (as well as trimming on the piece that holds the bearing in place). But on a positive note, the shaft starts lower in the engine bay and I now have at least 1/2" clearance from the header and the AC compressor. I haven't wired it up yet, but I think I have real estate to fit the control box high above the driver's kick panel, as my fuse block appears to be able to go on the firewall itself. And I got the rear bumper and some of the badges installed, in addition to finishing all the brake/clutch lines. Not a bad weekend!

[ADR]

Wow. That's a good bit of work. Please let us know how the EPS feels once you are driving it again.

What was your motivation to go for EPS vs stock?

[GoldHawg]

Those that have done it raved (e.g. BigTaku) and I have wider 205s all the way around, and I want my wife and daughters to enjoy driving it. I read a number of the Z-car guys say it was their best mod (albeit they are often autocrossing with super wide tires). If ever I was going to do it, this was the time.

[notoptoy]

Very impressive work, I'll bet that EPS is nice!