1 and 2- I used a 2002 Barina column. I referenced the Vauxhall column as that is what most of the info on the internet refers to. I cut up the main housing as the motor was in an unsuitable position. Ideally you'd find a left hand drive column or motor housing, these are available but like hens teeth and need to be imported. I actually found someone with them available new but it was too much money for me.
If you put the column in as it comes out of the Barina the motor sits too far to the left and fouls on the park brake and I think maybe also the console (or maybe it meant I couldn't easily operate the park brake), if you rotate it and put the motor to the right it ends up high on the drivers side and fouls on lots of stuff, so I decided it needed to be a mirror image so that I had a low mounted motor but on the right side of the column. So I cut the motor mounting flange off and put it on the other side, I made sure I maintained the correct relationship between the pinion/worm and motor mounting face. The layout of the area lets you simply turn the pinion/worm end for end and rearrange the bearings and it all fits back together easily. I added a spacer in between the housing and the motor mount when I welded it back together to allow for the changes and to be able to remachine the motor mounting face back to true. From memory I only used 6mm material, but also machined a couple of spigots to have the parts self align.
3- Nope, the motor shaft is standard, as is the Pinion/worm. Where these two meet is via a fine spline, male on the pinion, female on the motor, maybe only 10mm-12mm dia and the pinion has rubber shock absorters each end and this lets the Pinion move in and out of the motor coupling without anything bottoming out or binding.
4- The road speed trigger wheel sits inside the disc, I have HQ Drum Spindles with R32 4-spot calipers on custom brackets with UPC hubs and VT Commo discs. I don't have a pic with the wheel on, but can grab one if you like. There is about 10mm of the nose of the sensor sticking out past the caliper bracket. The UPC hubs already had the parallel dia and shoulder on them so I made sure my trigger wheel fitted without modification. All of this is done at home by myself.
5- The DC Input and the additional signal input connectors and wiring came from a wrecker, I called them up and they said yup no worries we'll just cut em out. The wiring for the trigger wheel sensor I made up myself (electronics tech by trade and jack of all trades).
If you want a bit more info, extra pics, I can add them to drop box or a google drive or some such thing and you or anyone else can see all the pics, good and bad, let me know if you want the extra info.
If I missed anything say the word and I'll try to clear it up a bit more for you.
I just noticed the pic I grabbed from the internet of a complete column is actually a LHD column!!! I already had the Barina column apart before I remembered to start taking pics.
Edited by mick_in_oz, 05 November 2018 - 08:02 PM.