[V8] Permanent Steering Rack Mount Fix

[toml99 at todomundo.com]

Hey all, now that the 5-speed runs, realized that the rack mount issue was critical and needed to deal with it asap.  Some of you remember that bracket I made up to "fix" it, but in reality it may have actually made things worse as it wasn't actually attached to anything in my case, as the fender metal was missing around the OEM bracket.  I had to drive the car about 20 miles to take it to my friend Dave's place on Lummi Island who's always up for a challenge/whatnot and is good at all things like this and cheerfully got dirty for 1.5 days of hassle.   I realized the strut had to come off, so couldn't just bring it to a welder in town, and say "fix it".  On the highway, I had almost 1/4 turn of the steering wheel slop, so took the corners slow, but was still fun to drive it after it sitting.  

Started dissasembly, and not wanting to sacrifice that TTY axle bolt, removed the inner and left it attached and dropped strut.  
Used a vibrating multi-tool(think Fein) with a new scraper blade, and removed the undercoat/paint/galvanizing quickly, that was quite thick by the way.  Drilled out the few spot welds that were still holding.  All the obvious cracks got welded before the 1/8" plate got cut out and hammered into that not even close to flat spot.  Fit like a glove.  That got welded thoroughly, then cut 3/4" strips(grinder) that got bent/welded to form the basic shape of what's there, but about twice the thickness.  Found a 2" chain link post that fit the hole perfect and Dave welded that in for structure.  If you look at the original piece, that oval hole/and no support on the front side is probably why they all fail in the same way.  Primed the patch with some Zinc Dichromate primer (Audi bathed the car in something similar)I had for painting lower units on outboards(think immersion in salt water), then sprayed the undercoating that still hadn't dried in 2 hrs.  Feeling like we nailed it, went to install strut, and it hit the left(front) side of new thing.  Looked at OEM, and it goes to zero (failure area).  Had to cut/grind in place with 1/2 dry asphalt/rubber undercoating getting hosed by sparks.  Worst part of whole project, but never thought the strut tower was that close to wall, and didn't even consider it.  Wanted to leave as much meat there as possible, but guessed, and it fit just fine.  Way beefier than stock.  Took a solid day and a half.  Would take 1/2 day next time around as most if it was fabrication decisions/what's there.  I saved the "ear" off the car, and my aluminum plate(that was super handy for lining up bolt holes, so the few of you that need to do this also, will benefit from that as I can trace everything out on some scrap and you can cut it out.  Hell, we both agreed that we need to patent this thing and somehow get a TSB requiring fix....Ha.  Goes down the road perfectly straight, and has about 1/32" of slop now....

Ran out the 1/2 tank of treated 3-4yo gas and it still ran rough at idle.  I had already dealt with the ISV and it was better, but still didn't sound like Lago.  Changed fuel filter, and there was about 1/2 shot glass of water in filter.  Ran better, but still not there.  Pulled first plug(#5) and electrode was burned to at least 2x the gap/fouled.  Pulled the rest(mint) and replaced the Autolite 103's with a new set($18), and it ran even better, but not perfect.  Today, decided to pull that one plug wire(newish but not Bosch) and check it and it was bad......swapped a crusty old wire on there, and all is good.   CANT believe that it was running on 7 cylinders that well.  Took it out on the highway, and it's feeling 100%.  Gonna get new wires/caps/rotors when I have money.  Had some punk in a WRX riding my ass, and had to torture him a bit....Ha. 

Jason, have no Bose stereo spares, and have a cluster, but I'm reselling the black car I sold to a friend's son, and it's got a bad speedo.....His has a peel of paint sticking out preventing needle from going over 35.  Speedogears.com or something like that had the plastic gear that fixed the last Saab I had if that's the only issue.  If I can get that paint peel out of way, may have one, but not really planning on spending any time fixing that as it's getting sold.  May drill a small hole in plastic and remove paint peel.....Ha.  Have another cluster, but is sunbaked/no LED screen/speedo say's 225K and I'd have to find it.  

Been wanting to fix that rack thing since I got the car in 08 so am feeling really good right now, and had to share the joy.....Cheers, Tom
 
http://tinyurl.com/zgdvv5b