Power Rack and Pinion Project

[pbrown]

It begins. I recieved the pump today. It's a KRC pump and bracket combo from Speedway Motors.

http://www.rainierfalcons.com/gallery/data/500/medium/KRC_Pump.JPG

The pump doesn't quite line up with the crank and water pump pulleys. I either need to space it further out to line up with the outer groove or trim the spacers to move it to the inner groove and relocate my alternator to the outer groove.

[BillP 98201]

Hey Pat
What do you think of heidt front ends thinking about switching to rack and pinion w/ power steering, and adding a t5 tranny. Got my new seat the other day. I really need some advice here. I have decided to work on the mechanics and do the paint later

[pbrown]

I'm not a big fan of the Mustang II setups for a couple of reasons.

1) It forces you to raise the engine a bit and move it forward to clear the crossmember. This might cause issues with your pinion angle and create radiator clearance issues.

2) The stock frame rails on a Falcon are really just made from sheet metal. They were designed to operate as a system with the rest of the unibody.

That said, if I were converting a Falcon to a M2 setup, I would go with the R&C kit. I would also add some DOM tubing from the front of the frame rails to the firewall to triangulate the system for more strength.

[BillP 98201]

:NERVOUS: Im lost.lol Where do I find information on that? Does the t5 idea sound okay? Thanks for your help

[pbrown]

Here is the website for R&C.

http://www.rcmotorsports.net/

Look over at TFFN and you'll find a lot of people that have installed this in there Falcon with good success.

The T5 is a great idea. Get the front shift option for the Falcon. Look at www.moderndrivelines.com (http://www.moderndrivelines.com) for that. They have a T5 where they swap out the tailshaft with one from a Chevy S10. That places the shifter in the close to the stock location.

[BillP 98201]

Thanks for the advice. Will look at tffn also. Looks like Ill have my hands full. lol :NERVOUS:

[pbrown]

I just placed my order for an RRS power rack and pinion kit. It ships from Australia. It will take about 20 days for delivery. I can't wait to get it installed.

http://www.rrs-online.com/rack&pinionproducts.php

[Nathan289]

Sorry butting in here.. ***Hi-jack warning***

I'm soon to be in the process of a T-5 swap.. Shows up Wednesday.. I'll let you know how it goes...


**** Back to your regulary scheduled topic******


Nathan

[Luva65wagon]

Nathan --

Why'd you go and do that for? :p

Back on topic...

Patrick, what front end do you have in there now? What are going to be doing with it?

[pbrown]

I have the stock steering box with a 1" sector shaft. The rest of the steering is 65 manual V8 stuff. I have no plans for it yet.

[Falconeer]

Patrick,
I could sure use your steering box, if its real good that is.Mine on my 63 is toast. The adjustment screw is bottomed out and steers like $&*#(@%.

Thanks
Butch Evans(Falconeer )
Thomasville NC

[falcon cobra]

Patrick.. I can't wait either, the rrs is really a good one ,I think I have looked at all of them, although it's the most $$ it looks better then the others. I could help on the instalation if you like...ps I have a heated garage with carpet on the floor if needed....john h:3g:

[pbrown]

Patrick,
I could sure use your steering box, if its real good that is.Mine on my 63 is toast. The adjustment screw is bottomed out and steers like $&*#(@%.

Thanks
Butch Evans(Falconeer )
Thomasville NC

Butch,

The steering box is yours if the shipping isn't a big deal. It has some slop and I've never adjusted it so I can't say what condition it's really in.

[pbrown]

Patrick.. I can't wait either, the rrs is really a good one ,I think I have looked at all of them, although it's the most $$ it looks better then the others. I could help on the instalation if you like...ps I have a heated garage with carpet on the floor if needed....john h:3g:

John,

I'll be doing the installation in my garage. You're welcome to join me. It should be a fun project.

[Falconeer]

Patrick,
App. the offer,but i found one localy. We puled the top off of it an there appears to be no ware on it at all.Seams to be in in great shape .

Thanks Butch Evans(Falconeer)
Thomasville NC

[Luva65wagon]

I'd be interested in the 65 front end stuff if you ever decide to get rid of it. I got 65 PS stuff from Jerry Kirby, but don't have spindles or any of the other parts that allow conversion to V-8 parts. I'm not sure what steering box is needed for this either, but I was under the impression that 65 and 62 boxes have different length steering wheel shafts -- but I don't know for sure.

[pbrown]

I'd be interested in the 65 front end stuff if you ever decide to get rid of it. I got 65 PS stuff from Jerry Kirby, but don't have spindles or any of the other parts that allow conversion to V-8 parts. I'm not sure what steering box is needed for this either, but I was under the impression that 65 and 62 boxes have different length steering wheel shafts -- but I don't know for sure.

You can use your old column. The pitman arm, center link, and idler arm will bolt on. I have a pair of 65 Mustang V8 spindles if you need them. You would need to find the drums or buy an aftermarket disk kit for them. I have Granada disks and spindles now. They will stay for now but I plan on getting a Wilwood disk kit to use on some 70 Mustang spindles I already have.

[Luva65wagon]

This is a future project, so I'm not in any hurry. Just collecting stuff as it comes about. I keep looking for Granada's in the Pull a Part, but it seems I'm always a day late, dollar short. Sadly, I had a set before and gave them away. Oh well...

[pbrown]

The R&P kit has finally shipped a couple of days ago.

[modified17]

I have a set of 63 V-8 spindles and drums still on an old clip. You can have them if you want. You can call me at 425-481-1502 Dave

[pbrown]

The rack is here. FedEx delivered it this morning. Now the fun can begin :shift:.

[falcon cobra]

Hi there patrick.. so when does the fun begin? before the swap meet or after? I hate waiting for goodies to come ups,fedx,ect,ect.....it sounds like a great switch, the old boxes are not worth a ----. r&p is the only way to go....let me know....john h

[pbrown]

.. so when does the fun begin?

I'll try to get started this week. I'll be working the swap meet on Saturday. I'll be working on it on Sunday. Visitors are welcome.

[Luva65wagon]

Weren't you going to bring stuff to the swap?

[pbrown]

Weren't you going to bring stuff to the swap?

Yes. I'll coordinate that with Kenny an Jeff in light of your truck issues.

[falcon cobra]

Hey patrick.. do you still get to use your granada spindles with the rrs-r&p ? the people at tci [that also make a fine r&p] say one needs late 70-73 mustang spindles...something about bumpsteer, they thought they work better than the granada's....what do you know about that?? thanks..john h

[pbrown]

Hey patrick.. do you still get to use your granada spindles with the rrs-r&p ? the people at tci [that also make a fine r&p] say one needs late 70-73 mustang spindles...something about bumpsteer, they thought they work better than the granada's....what do you know about that?? thanks..john h

The Granada spindles will work as well as they do with the stock steering. There has always been a bumpsteer issue with them.

I have a set of 70-73 spindles that I plan to switch to when I upgrade to Wilwood brakes.

[pbrown]

I started work on the conversion. I'm working on removing the old stuff. I ran into a snag on the pitman arm. I need to rent a puller to get it off.

I disconnected the seven wires that connect the column to the under dash wire harness. That was fun hanging upside down under the dash. The steering wheel is pulled.

I'm hoping that I can remove the steering box and column from the inside. I don't think I can get it out from under the car without pulling the header. I would like to avoid that if I can.

[redfalken]

I got a chance to see Pat's new set-up after the swap meet. Very nice! It looks like a really well made unit and should be a clean install.

In other words...sweeeeeet! [thumb]

[pbrown]

The old column is out. That came out easily from inside.

The steering box is another matter. I was able to remove it but is was a bit of a chore. had to pullthe drivers header, the belly bar, and jack up the left side of the engine. In the end, I cut the steering shaft short to make it come out easier. Sometimes, after removing a lot of parts, I wonder. What is the very first part attached to a bear chassis? I don't know if it's the steering box but is close to the top of the list.

I cleaned up the frame rails and bolded the new rack in. It looks good. I had to remove the belly bar as the new rack doesn't fit with itin place - bummer. It looks like there might be an issue with oil pan clearance. This was mensioned in the instructions. I will probably add some 1/8 - 1/4" spacers to the engine mounts.

[pbrown]

Here is a photo of the progress.

http://www.rainierfalcons.com/gallery/data/500/medium/Rack_Installed.JPG

[falcon cobra]

Patrick,, it looks like it's comming along well, will it clear a stock pan? or is yours the same as stock...how close to the starter does it come? sure hope it's better than the old box..but then, anything should be better than the old box...john h:BEER:

[pbrown]

will it clear a stock pan? or is yours the same as stock

It looks to be just touching. I have a Milodon pan that is a stock style unit. It looks like it needs to be cleaned. The instructions mention having to shim the engine up a bit in some applications. I picked up some grade eight washers this morning. I try to add them between the frame mounts and the intermediate mount and see what happens. I don't think it needs much.


...how close to the starter does it come?

It's close to the starter but doesn't touch. There is still room for the transmission coolant line to make it through.

[falcon cobra]

So how's it going ? patrick..by the way did you sell the R&P you had up at the swap? if not I will take it off your hands,,,for $$ ? thanks ....john h:banana:

[pbrown]

So how's it going ?

I did some work tonight. I'm sorting out the column stuff now. I still need to shim up the engine a bit.


..by the way did you sell the R&P you had up at the swap? if not I will take it off your hands,,,for $$ ?

It didn't sell on Saturday. I suspect that is didn't sell Sunday either. It's yours for $40.

[Luva65wagon]

I guess you didn't get this PM I thought I sent you guys -- apparently only Kenny got it:



Well today was v - e - r - y slow and the only thing that sold was some rack-n-pinion which I don't know who's was -- but I left the booth to be tended by my friend Bill and he took $20 for it. I never even noiced it though I probably moved it a dozen times I'm sure.



Sorry about that...

[pbrown]

I did a bit more today. I have the U-joints in place. I had to drop the rack to get them in. It was too tight to just slide on.

The column has been modified and painted.

The plumbing is done. I used Russell teflon lined high pressure stainless line and matching -6 AN ends. I only stabbed myself once. Those of you that have built stainless hose assemblies know what I'm talking about.

I have the column in the car temporarily. I need to do some work down at the firewall where the column goes through. There is a 2.5 turn lock to lock with this system.

I found that the kit included motor mount spacers. I installed those and the rack clears the pan perfectly. That was fun laying under an engine with one mount off.

[falcon cobra]

So how is it going patrick.. are we on the road yet? waiting for a report, or maybe you went away for the holiday....john h

[falcon cobra]

WE must read minds... check out the time of the last posts

[pbrown]

WE must read minds... check out the time of the last posts

Spooky.........

[pbrown]

More progress. I mounted the column with the lower column support. It seems that the intermediate shaft sent with the kit is one inch too long. I guess that is better than too short. Anyway, I took a measurement if the distance between the upper and lower U-joint and make the cut. I'm now at a point where I need a helper to insert the column while I line up the U-joints and shaft. I tried doing in solo but it just won't work :(.

I also have to go to Schucks for the third time to find the right length V belt. The first was just a bit too short. I returned that and asked for a belt that was 1" longer. It is actually about 6" too long :mad:. I might just go buy four or so belts and return the ones that I don't use.

[Jeff W]

Pat, I can come over this weekend for a couple of hours if no need. Call me. Jeff

[pbrown]

I was able to get more done this morning thanks to Jeff. We have the column mounted and U-joints connected and tightened. All of the critical bolts have thread locker on them.
We had to make run to Schucks to get the right belt. This was the third attempt at getting the right size. The new belt fit great.

I still need to connect the horn and turn signal wiring for the column. I'll either do that this evening or tomorrow.

I installed the front wheels and took the car off the jack stands. I can say that the turning effort is greatly reduced. I'll take it out for a test drive tomorrow and will take it for an alignment on Tuesday.


There are some issues to work through:

1) The upper column section didn't allow the steering wheel to go on far enough. I have about a 1/4" gap from the back of the wheel to the column flange. This means that the horn and the turn signal cancelers won't work. I need to contact RRS to get there advice.

2) The horn button won't go on. The new shaft protrudes too far for the horn ring to seat. It looks like I can just drill a hole in the horn contact plate with a step drill.

3) There is a small amount of play there the upper and lower column sections go together. We pulled the upper section and added axle grease and this seems to help with the noise.

4) There is nothing to prevent a driver from pulling the entire steering wheel and upper column section right out of the car if they were to give it a good pull. I don't know what I think about this. The later Mustang columns use a bearing retainer. The early Falcon does not. I'll do some research and see how I might resolve this.

[falcon cobra]

It sounds like it's coming along well, there is always some bugs in projects,not sure why,but there is...your old pitman arm is it a 6cyl or a V8 type??I met a guy that need a V8 type and maybe the old box..thanks john h

[pbrown]

your old pitman arm is it a 6cyl or a V8 type??I met a guy that need a V8 type and maybe the old box..thanks john h

My old stuff is all 65 V8 Manual Falcon stuff. The pitman arm has a 1" sector shaft hole. The idler arm is the two bolt style. The center link is a reproduction 65 Falcon unit.

Sadly, the steering box did not come out in one piece. I tried. I kept removing anything that was in the way until I realized that the engine was in the way. I wasn't willing to pull the engine to save a worn out steering box. What is left of it is in my recycle bin.

[pbrown]

I finished up the little details. This included the column wiring, drilling the horn ring to clear the shaft, installing the drivers seat, and installing the carpet. I still have the gap at the wheel to deal with.

I took the car for a short drive. It is very different. It drives in a straight line with no wandering. I took it to Golden Gardens park to test the turning radius. It seems just fine. I can even get out of my own driveway much easier.

I'll be taking it for an alignment on Tuesday.

I'll be at the Ford Picnic next weekend if anyone wants to see it.

[Luva65wagon]

So what did you have to do to close up the gap in the steering wheel to column? And what keeps you from pulling the wheel off as you indicated earlier? FWIW, the 67-72 F100 use the same column, but have two bearing sets, upper and lower and there is a clamp at the base you can adjust the placement to determine how far the shaft protrudes up top. So, what's now down low considering the "box" used to attach to the column? Inquiring minds want to know.

[pbrown]

So what did you have to do to close up the gap in the steering wheel to column?

The gap is still there. I will probably have a machine shop cut another set of grooves for the circlips to lessen the gap. I still plan to contact RRS to get their input.


And what keeps you from pulling the wheel off as you indicated earlier?

Nothing. I can change to a Mustang column. The Mustang has a bearing retainer. I may experiment to see of the retainer can be retrofited to the falcon column.


So, what's now down low considering the "box" used to attach to the column? Inquiring minds want to know.

The old shaft is replaced by a new two piece unit. The upper is solid and the lower section is hollow. They are keyed so they won't spin. The column tube is cut at the firewall and a bearing is placed there to support the bottom section of shaft. There is still a bearing at the top so the new shaft is supported at both ends. The converted column is connected to the rack with two universal joints and a short intermediate shaft.

I'll get some photos posted later.