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Our 2025 car switched from a straight steering column to a U-jointed column to improve driver comfort and ergonomics. I sat in last year's car holding the wheel where it was comfortable and took measurements from the wheel to the frame. I put these measurements in the suspension geometry CAD referencing off of last year's frame and this year's seat position. I used this to get the correct lengths and angles of the steering column.
The lower section is carbon fiber to save weight (this was done with success on the 2024 car). The upper section is short enough that it made more sense to make it a turned aluminum piece. In order to make the system capable of disassembly, I made the upper tube detachable from the u-joint using coiled spring pins to secure the two components and transfer torque while still being removable.
Brass bushings allow the upper tube to spin freely while being adequately supported and grease prevents premature wear of the bushings or column.
3D printed fixtures for bonding lower carbon fiber tube.
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