Meanwhile, it's time to get down and dirty and WORK while I save money for RWC and rego.
Step 1: Put a decent clutch in there
Current "Extreme" 6-puck clutch and cheap
plastic thrust bearing are RUBBISH. I know, the plastic thrust bearings are normal, but I go all funny when I see them.
Step 2: Power steering just HAS to go. Sorry.
Step 3: Make an idler for the drive belt in place of the power steering pump
1) My idea is to make two long bolts to thread in place of the standard pump mounting bolts.
2) A tight nut up against the motor will keep the threaded bolts in place
3) Make a sturdy bracket to slide over the two threads, and use a nut on either end with loctite and lock washers to keep it in place
That way the bracket is depth-adjustable, so I can line it up peeerfectly with the rest of the serpentine belt
4) Bolt an idler pulley onto that bracket. The only problem is that finding the right pulley is a pain, so I've had to use some inventive shims:
Now all I need is two reeeally long threaded bolts. Since this project is being done on a budget, I'm making bolts on the principle that spending money is BAD!
Here's how you turn short threads on old bolts into brand new long threads:
And here's the basic mockup of the bracket I'm going to use. Tomorrow I'll trim it down, tap it to accept the idler pulley bolt, and see if it all works
More pics to follow, it'll make more sense then
(to come) Step 4: Install manual steering rack, modify intermediate steering shaft to fit, finish idler pulley and find correct length belt
(to come) Step 5: Install PBR Heavy Duty clutch, solid billet thrust bearing, etc etc
(to come) Step 6: New uni joints in the tailshaft, may aswell while it's out
(to come) Step 7: RWC