April 2016

After my disappointment with both my implementation and the general look of the Mk 3 Escort stalks I managed to get some Mk5 stalks along with connector plugs.
I also get a complete pair of the steering column cowls or covers along with the air bag spiral cable assembly which also contains the indicator self cancelling ring and horn contact ring.
I dismantle the airbag spiral assembly and remove the horn ring/indicator cancel ring.

I figure the easiest way to mount them will still be with a boss secured to the upper steering column guide bracket.
I get a round length of aluminium and machine such that one end is large enough to mount to the steering column support.
The next section is turn down to the diameter of the stalk assembly.
Finally I leave a section extending past the stalks towards the steering wheel. This will assist in locating the horn slip-ring/ indicator cancel post.
I then bore out the centre to allow the column to slide through.
A trial fit appears promising, the stalks sit snuggly around the mount and the slip-ring is perfectly aligned at the end.

The lengthy contacts are cut from the slip ring - I will solder wires on later.

I need something to insulate the slip ring from the steering boss. A section of black delrin is machined in the lathe with recess to locate it on the steering boss.
Clearance holes are made for the crumple zone securing screws and recesses to allow the wiring from the slip ring through two holes made in the boss to reach the
steering wheel centre horn push button.

Finally the sides of the mount are machined at an angle each side to allow clearance for the connectors and wiring from the stalks.

When it is all fitted to together it looks quite neat, but when on the shaft and sitting flush to the column support behind the dash the steering column rubs on the
internal bore. Although I will bore out the hole larger, I still need to figure out what is worng. I will come back to this.
I also need a longer stering column and to figure out the wiring.