Time for an update:
So , the conversion has been completed and it was a total success. The aircon was stripped out and thrown away , it was leaking oil anyway, ill take the 20kg weight reduction cheers [smilie=karls_thumb.gif] . To get the DC5 rack to fit in the EP3 correctly the inner arch had to be "sculpted" (hit with something blunt and heavy) until both full left and right lock could be achieved. There is also a 5X3 inch rectangular hole in the inner skin on the bonnet to give the large power steering pump pulley the right clearance. The exhaust manifold heat shield had also to be removed to make room for the hydraulic line routing. The only other noticeable cosmetic difference is that the EPS light is now on permanently in the dashboard. So not the conversion who like their cars OCD perfect
. The only thing missing from the conversion at the moment is the DC5 clip for the reservoir, it is currently cable tied on and the clip is on order.
I managed to drive the car briefly (for reasons i will get to in a minute) and the new hydraulic steering feels brilliant compared to the old system. I always felt like the EPS let the car down, as evo magazine said about the EP3, "Potent engine, drivetrain and chassis, duff steering - 4/5 stars". The hydraulic steering feels heavier than the EPS steering, the old "kick" i felt in the EPS steering when moving off centre is gone. The steering "feel" is completely different than before, i think the best way to describe it is that you can feel things happening through your finger tips that you just missed entirely with the EPS set up. For example, when the road surface changes from smooth to rough you actually feel tiny virbrations through the wheel. You can also feel your diff working when you are pulling out of junctions or on an uneven road. Definitely a nice upgrade IMO. I will learn alot more about how well it performs when i take it on track.
Unfortunately, on the test drive there was still a loud click coming from the front of the car after the conversion, although the old rack was nackered it turned out not to be the source of the original problem. Turns out my front driver side coilover is completely fooked. When the car was on the ramp you could get a good 5mm of play in the wheel. This has been stripped and sent off to KW to get rebuilt (lifetime rebuild warranty FTW).
They have only been on the car for 1 year (6k miles) so i was initially pretty annoyed with this as KW are supposed to be very good coilovers. I then remembered that a couple of months ago, i hit a pothole on the M73 at about 60mph that was so large the front end of the car jumped. At the time i though i had killed my driver side wheel, as there were 2 cars 100 meters down the road pulled over onto the hard shoulder with flat tyres. I though i had got away with it but it seems that the impact obliterated the shock absorber.
When i get the car back on the road i will take pictures of all this stuff and post it up. Hopefully this will be all my bad luck with the car used up!