The Flaming River Motorsports...
The Flaming River Motorsports Electric Power Steering assembly is approximately the same size as a typical power steering box, but instead of using a power rack or box and the accompanying hoses and pumps, it operates off of the small electronic steering controller (ESC), also known as "the brains" of the unit.
We got our first look at the new Motorsports Electric Power Steering system from Flaming River when the company sent us a new-product announcement a while back. We finally got to see the piece up close when Chad Blundell from Blundell Speed & Machine called to tell us he was installing one on a customer's '40 coupe.
The car's owner wasn't enjoying the exercise from the manual steering rack, and came into Blundell's for a more mainstream power steering setup. A 327 small-block sat between the stock unrecessed firewall and the crossflow radiator; there wasn't much room left for power steering with the addition of an alternator and A/C condenser, and several other shops had told him they couldn't do the job without tearing apart the whole front end, adding a serpentine belt system, relocating the alternator and condenser, and trying to stuff in a PS system.
Chad figured the Flaming River system (PN FR40105) might be the best solution. The kit comes with the motor assembly and ECU computer that responds to steering input-including driver resistance preferences as well as speed and wind resistance, and road and tire resistance-and can be used with manual rack-and-pinion or manual steering box systems. As the ECU senses pressure changes, it adjusts the motor to respond accordingly. There is no power assist under straight-line driving. The system runs off of the ignition source, and draws only about 5 to 8 amps under ordinary conditions, and never more than 25 amps. If power is lost, it reverts to manual steering.
To free up some room under...
To free up some room under the dash, the GM full-length tilt column was being replaced by a 17-inch Flaming River Micro Tilt column equipped with the ignition and shifter. The steering wheel would also be replaced with a banjo wheel during the swap.
This is definitely not a low-buck way to go. With a retail price of right around $6,000, it's certainly not the cheapest way to steer your car, but for some rodders, it might be the smartest. It might also make sense if you factor in the cost of a new rack, accessory drive system, and any other modifications that might need to be done, as well as the downtime of the rebuilt.
Flaming River advertises that the Motorsports unit requires the fabrication of a mounting bracket for specific applications, which is what Chad was up to when we dropped in.
In addition to where it will fit, there are all kinds of considerations when fabricating the bracket. Column angle is particularly important and can be adjusted with U-joints, but ideally the system should run as straight as possible with a minimum of U-joints. The location of the shaft through the floor and the position of the column at the driver end must also be considered. No part of the system should interfere with the pedals. Any levers at the upper end must be able to clear the dash and be reasonably comfortable to use. By running a Flaming River Micro column, Chad was able to make things a little easier, but he added some challenges by running a column shifter. He also wanted to make the installation "plug and play" as much as possible, meaning that the components can be unbolted and removed easily in case the unit needs servicing or some other underdash components need to be accessed.
A further consideration was that the bracketry had to be beefy enough to handle the resistance in the steering. The bracket has to withstand the rotational torque going into the system as resistance increases. When building a bracket, remember that it's doing more than holding a 12lb part; it's trying to resist the torque being generated by the steering system.
The '40 was one of the first customer hot rods to be equipped with this new Flaming River system. Since they are generally designed for use with floor shifters, the manufacturer was eager to see how Chad planned to pack one under the dash with one of FR's tilting shifter columns. We were too.
A few ancillary modifications...
A few ancillary modifications had to be made to fit the new column. Chad milled a notch in the top portion of the swivel upper column drop to accommodate the mechanical rod from the ignition.
Making that happen, however,...
Making that happen, however, was going to take some fabrication. Chad's solution was to create a simple bracket to position the unit underneath the Micro Tilt column inside the car.
Chad ordered the steering...
Chad ordered the steering column with a 3/4x36- spline output shaft (the same spline as the input side of the unit). A coupler mates them together.
The unit can be mounted on...
The unit can be mounted on the outside of the firewall (which is how Flaming River did it on the '32 roadster on display at the SEMA Show), but it made more sense (and more of a challenge) to hide it up underneath the dash on this '40.
From this angle, you can see...
From this angle, you can see one of the two straps already in place on the car, which will be used to help secure the column and steering unit.
When Chad was satisfied with...
When Chad was satisfied with the positioning of the steering column, unit, and steering shaft, he fabricated a bracket to hold everything in place. The two remaining cylindrical bushings bolt to a pair of pads on the steering unit. Welded to the bushings are arms made from flat stock bar.
The plate was designed to...
The plate was designed to match the contours of the firewall and is large enough to spread the load from the steering unit. It will be fastened in place with three 1 1/4-inch flathead cap screws, with 5/16 national fine thread, and billet countersunk washers, and Nylock nuts to absorb vibration.
Careful planning when setting...
Careful planning when setting up the system means that, from the output side of the system, a single U-joint is all that was needed to line up the 3/4-inch stainless double-D shaft through the hole in the floorboard. The less U-joints and turns the better, as on any steering system.
The ESC could have been mounted...
The ESC could have been mounted virtually anywhere, but a few additional pieces of strap keep it snug next to the steering unit. Another alternative would've been to hide it behind a kick panel.
Before final assembly, the...
Before final assembly, the system was painted flat black to make it less noticeable. We were impressed by how well everything tucked up underneath the dash and-more importantly-cleared the gas pedal and brake pedal.
We had to stoop to see the...
We had to stoop to see the unit underneath the dash. It's even less noticeable when you're sitting behind the wheel or in the passenger seat.
The only outward clue that...
The only outward clue that the unit is in place is the small knob on the dash that operates the potentiometer, allowing the driver to adjust steering resistance by simply turning the knob to several preset levels of sensitivity.
Ultimately, the only thing...
Ultimately, the only thing that matters is whether or not the driver is happy. Car owner Hal Motley took the coupe for a test run around the neighborhood and came back with a big smile on his face.