Steering Rack - Mounted

Another good weekend. The steering rack is mounted and works! A quick check showed no noticeable bump steer over -1 to +2 inches of wheel travel. Next I need to get some u-joints and a collapsible section for the steering column. So far I've had some trouble finding a u-joint with a splined end that matches the rack (9/16" x 36 teeth). Need to make some calls...

Steering Rack Modification - Continued

This turned out to be a productive weekend. I was able to put in 8 hrs and finished modifying the steering rack today. Here are some pictures of the finished rack (not assembled though...)



Here's a picture of the method I used to determine the rack length and approximate placement. Tools used were 2 rubber bands, a string and tape measure. When I mount the rack I'll adjust the height to minimize bump steer.

Steering Rack Modification

The steering rack I bought is 24" between pivots. Based on my suspension geometry this distance needs to be 19" to minimize bump steer. After thinking about the best way to do this for some time, I decided to cut a section out of the middle of the rack and weld it back together.

I started this weekend. Here's a pic of the steering rack shaft and housing. The housing is already cut into three pcs.

Next I cut a 5" section out of the rack, then squared and beveled the ends using a 12" disc sander:

Next step will be to fixture the pieces so they are aligned, weld together and grind smooth. I'll use the same method to shorten the housing.

Suspension Update

Front and rear suspensions are 95% complete. I was able to suspend the car on all four uprights and bounce up and down...felt pretty good. Front seems a little stiffer than the rear but it's hard to tell from just jumping up and down.














After assembling the front suspension I was a little worried that the outer steering tie rods would contact the lower a-arms. Today I checked clearance and...it looks like it will be close, but should be okay. Can't be 100% sure since the steering rack isn't mounted, but I'm feeling good enough to move on.

Things left to do on the suspension:

- Confirm wheel rates (probably will use sand bags for weight and measure deflection, Tyler need sand for his sandbox anyway...)
- Design and machine bellcranks - I made temporary ones out of flat stock to test the suspension but they probably wouldn't last more that a few good bumps.
- Cut steel sleeves for front suspension bushings. The ones that came with the polyurethane bushings aren't the best quality and vary in length...looks like they were cut with a chop saw.

Next stage: determine optimal steering rack length and mounting location, then figure out the best way to shorten the rack...