Terminator Roadster Build by cChrisM - MK3 7011

The plan with the build was to use as much from the Mustang as possible, ie power brakes, steering, ABS, traction control, etc.

The 2003 Mustang used a Hydro boost system which powered the brakes and steering. The hydro boost unit needed to be modified for mounting. Part of the unit had to be removed so an aluminum mounting spacer could be added.

The 99-04 Mustang V8's steering rack came with a 2.62 lock to lock turn ratio. The 03 Cobra had an improved 2.38 lock to lock and also incorporated built in limiters to handle wider tires. The Terminator steering rack has generally been considered an upgrade from previous Mustangs. The Terminator rack benefits from an increase in thickness of what is known as the torsion bar, or "T-bar", which gives the rack its firmer feel. The torsion bar is actually a part of the spool valve assembly which composes the pinion, as in "Rack-and-Pinion".[url]http://www.terminator-cobra.com/images/Pinion.jpg[/url] In addition, the SN-95 Mustangs in Cobra & GT form use the higher-flowing Motorcraft C-III pump for better assist. The T-bar, it fits inside the spool valve and is connected to the steering shaft at one end, and the pinion gear at the other. In essence, it acts as a spring, and the twist of the T-bar is what controls the flow of fluid through the valve assembly. The thicker the T-bar, the "harder" it is to turn the wheel, giving the rack more of a "firm" feel. In the case of the Terminator, the T-bar has a thickness of a 0.230". If you wanted an even firmer feel, the next step up would be to a 2000 Cobra R rack, which I believe has a slightly thicker 0.245" T-bar (although I have heard many variations on that).

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Mounting the steering rack. At build school they advised to get the offset aluminum bushings from Breeze which centers, lowers, and pushes the rack forward. This will reduce bump steer, which is the darty steering you get when going over bumps. The donor has rubber bushings as well so the solid aluminum would provide better steering response. The mod required grinding the frame to get the rack in the correct spot and allow the rubber boots to fit.
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The donor has a power steering cooler which consisted of a long loop for the power steering fluid that wrapped around the front of the car. I opted for a small cooler mounted out of sight. Over kill compared to the donor. Welded in some tabs (not shown in below) and a bracket for easy mounting.
[IMG]http://i560.photobucket.com/albums/ss43/cChrisM/The%20Build/DSCF0006-2.jpg[/IMG]
Next step was to install steering shaft. Since the alternator is in the way, I followed Sergio and added a knuckle to go around the alternator. What I later found out was that when flipping the exhaust manifold around it would hit the alternator, so the alternator had to be moved to the passenger side of the engine. There goes my hope of having Air Conditioning. With the alternator moved I sold my modified steering to another Terminator builder and got his straight shaft. A ton of fabrication and time down the drain.
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The next step was to make power steering lines out of AN Fittings and lines. Followed diagram from other builders.
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Mounted the powersteering resivior on the driver side off the frame, normally it is connected to the motor.
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Moved alternator to passenger side via a bracket from Wayne Presley (modified original bracket)
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