PAS: Defender upper column (part 1)

I have taken a template and measurements of the parts required for the PAS box to the local engineering shop, and expect to have the plate and four gussets by the weekend.  They will also be able to tap threads inside the P38 drag link once I cut it to size.  Big progress has been made on the steering column.

I spent a disproportionate amount of time getting the old steering box and column, but getting the Defender upper column in was easier.  To do so required the removal of the steering box cover and mudshield (disappointingly rust for a zintex panel that was covered in Schutz when first fitted in 2006 – it is that which has left the stains and flakes on the foot well, the foot well itself being sound)).  Getting the drop arm off the steering box rocker shaft was a pig, but it eventually came free with the use of a big ball joint splitter (I couldn’t get an appropriate puller).  The steering wheel, column shroud, indicator stalk switch and ignition/steering lock assembly were all stripped off and the clamp on the front side of the bulkhead was removed.  To allow the rocker shaft to clear the support bracket, the brake pedal box had to be moved up and aside, which was a tricky job without disconnecting the hydraulics – the steering column covers the base of the pedal box and the wing top is very close to the servo, so everything gets in everything else’s way.  I eventually got it clear, and with a bit of juggling, got the old column and box out.

After refitting the pedal box, I slid the Defender column up between the two pedal boxes and into position.  With it pressed up as far as it would go, I fit the SIII ign/steering lock, followed by the SIII upper column clamp on the front of the bulkhead (dimensionally identical to the Defender version, but doesn’t have the big back plate that was fouling on the clutch cylinder reservoir when I tried it).  With the column fitted at its top end, I installed the column switch gear.  I will fabricate a bracket for the bottom end to secure the existing lugs to a lateral bar, in turn bolting onto the original steering box mount using the existing bolt holes.  Given my welding, it may take the bulk of the morning, but should be relatively straight forward.  Getting the paint to dry before fitting is probably the bigger challenge in this weather; I may have to stink the house out by letting it dry in the kitchen.

So, the lower bracket and wiring up the column switches are tomorrow’s plan.  The idea is that the dash switch functions of lights, fog light and front wash/wipe will be relocated on the column, just the heater fan staying on the dash.  The lights and fog light switches on the top row will be replaced with guarded toggle switches, one of which will isolate power to the rear work light, and the other will trigger the split charge replay (bypassing the alternator charge light) so that I can use the auxilliary battery for engine starting should the main battery be depleted.  I will also try to find a fan belt from a motor factors for the PAS pump (30-34″ total length should be about right) so that I can start mocking up the pump bracket.