JB in NOVA's MK4 build : First overnight road trip!

[JB in NOVA]

Well, installing the power steering rack was an adventure, but I got it done! To bring the thread up to date, I decided to go with PS a few weeks ago while I was waiting for my LCA’s to arrive. Actually, I had originally wanted to do PS from the beginning, but I talked myself out of it when I ordered my complete kit because I thought it might add too much complexity to my build. Back then, I was trying to adhere to the KISS principle. But the more I researched it, the more I felt it was something I could probably handle.

I ordered an OEM replacement PS rack for a 1989 Mustang from Rock Auto. I also ordered Breeze offset solid aluminum bushings, which many on this forum have praised. I actually got a very nice call from Mark Reynolds from Breeze, who responded to a web query I posted about PS. It was nice of him to spend some time talking to me (a newbie) about how to install power steering on my Roadster.

Everything arrived in short order, and last night I began tackling the project. The first step was to remove the existing bushings, which was fairly easy with some taps of a hammer. The next step was to install the Breeze solid aluminum bushings. Some have said their Breeze bushings slipped in with ease, but mine did not. They were very snug, but I was able to get them in with a rubber mallet:



The next step was to test fit the rack on the frame. Like many have reported, I experienced some difficulty getting the passenger side bolt through the rear bracket. I did a lot of sanding with 100 grit sandpaper wrapped around a dowel, but I still could not get it through:



Eventually, I used a grinding tool to open up the hole enough to get the bolt through, and that worked fine.

The next step was to trim about 3/8 inch off the front rack mounting brackets (AKA rear LCA brackets) to avoid interference with the rubber boots. I used a Dremel cutting wheel and grinder to do this, then I primed and painted the exposed metal. I think it turned out OK: