Had some me time

[B67FSTB]

Guess what...found an 8 inch rear end in the shed....so I had to extend the rack.
Why so many rear axles? When I see a bargain I can't let it go.

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[Horseplay]

I can't see if you may have done so but I highly recommend you fasten the top of the rack to the wall now. The chance of it tipping forward with so much weight that high does increase the likelihood of an accident.

 

[B67FSTB]

You must know me Terry ! Secured it with 4 bolts to the wall .

 

[B67FSTB]

OK.Today was a all rainy day and I decided to tackle the cowl....again.
Despite all comments I decide to put the upper and lower together prior installing on the car. I want to be sure the wiper pivots are a bit in the center of the holes in the upper part. I used some copper tubing to center them. Next was drilling about 100 holes in the lower part. And afterwards to weld both pieces together.
Next will be grinding the welds flush.

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[Aussie67]

You're meant to fix the holes, not make them.......bet you were happy once they were all drilled.

 

[B67FSTB]

More happy when all the welds are grinded flush !!!

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[B67FSTB]

Took the laser to check if the cowl assembly did not twist during welding. Looks to be OK.

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[B67FSTB]

Temps outside are going down. Before storing the stang for the winter I wanted to change the orignal power steering to a borgeson setup. Removed the instrument cluster , steeringwheel and column . Masterbrake cylinder went out and already removed centerlink with slave cylinder.
I want to save the orignal steeringbox so I have to remove the pitman arm from the steeringbox. It doesn't move !! Man , I think I will regret this swap ! It took me 7 hours to do all this and the pitman arm isn't removed from the steeringbox. I am beaten for today. To save the steeringbox , I have to dissemble it in the car. Meaning remove cover , remove pitman arm so I can push the sectorshaft a bit upwards so I can pull the long steeringshaft out of the box. Thats the plan.
Or...remove the header... another pleasant job
.

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[B67FSTB]

After a good night sleep and some thinking , I decided to tackle the job different.
I remove spark plug cables , spark plugs , LH header and LH valve cover. I then could remove the whole steeringbox out off the car !! Job done !!
Next installing Borgeson box and measuring and cutting column. And cutting an old worn steering shaft and grind a double D so it fit the rag joint at the box.
That will take time. Like they say : measure twice , cut once....or was it the other way around ????

 

[Horseplay]

Bruno, not sure of your plans for the pump to use with the Borgeson box but I recommend tweaking it to lower the output pressure. I used a Saginaw style pump and a replacement valve that reduced the output pressure about 30%. It still provides really good assist levels but not so much as to remove too much "road feel".

 

[KBMWRS]

This all better be on the road by next May.

 

[limeyboy]

Bruno, given we have the same type of roads do you rate the Borgeson to be a worthwhile change over standard?
I've replaced / rebuilt all the steering on mine except for the steering box which is worn but not too bad and I'm not sure if the cost is worth it for me.

 

[B67FSTB]

Ok. I scrambled the parts together over the years cause I am on the budget...as always. I noticed that you can use the orignal Ford p/s pump when buying the hoses. So , I choosed the hoses for the Ford p/s pump.
How good it will work , I don't know but heard alot of good thing of this conversion. I'll have to wait and see/feel . I exspect more roadfeel from this setup. Above 45mls/hr the p/s
should feel sturdier IMO.
I guess by next may it should zll be good !

Today I tackled the steeringcolumn. A bit scary to cut a column or the shaft cause I only have one and its not an easy buy overhere !
Installed Borgeson box and measured from the clamp that holds the column. I must say all went very good. Had to cut once and all is good. In pics some measurements of all the pieces. Hope this can help someone who will tackle this conversion.

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[B67FSTB]

After measuring and cutting the column , I assembled steeringwheel with shaft and column as a whole. Took some measurements of how much the shaft has to be cut. Grinding with cloth sandpaper so the lower bearing will fit. ( self engineered) .

Final I assembled it all together and checked clearance between column and steeringwheel.

Next will be making double D at the end of the shaft. Wish me luck.

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[Horseplay]

Nice work so far, Bruno. I remember being a bit nervous cutting down the column too.

The improved feel of the Borgeson set-up vs. any "rebuilt to new" 60's power steering system that I ever drove is HUGE as long as the other mechanical bits of the steering linkage are in good shape. When I first drove mine I had a 2014 GT and would say the '65 gave me a much better sense of the road and, to my preferences, a better feel at the wheel. I will repeat that reduced pump pressure was a key to making wheel input critical to my satisfaction.

I can't wait to get the truck on the road so I can do some real life feel comparison to it's electrically assisted system. Truth be told I expect to still prefer the Borgeson but that was not an option I wanted to go with running the flathead.

 

[B67FSTB]

After making the garden ready for autum and winter and trimming 120m of hedges , I took time to make a " tool " so I can make a " double D " at the end of the cut steering shaft. I want it to be precise so it sits firm in the rag joint.
I have a pneumatic grinder and a carbon "cutter" . Did some measurements , zip tight it , make some reinforcements and guidances. I gonna take the nut as a template to grind the other side at exactly 180 °
You all have to wait for the result...

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[B67FSTB]

Succes !! With the first cutter is did not work cause...it had no bite at all. Found another one but was slightly smaller in diameter.
After a little adjustment I could "shave" the shaft .
I am very pleased how things went . Exactly how I imagened it in bed , very early in the morning.

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[KBMWRS]

This guy is good.

 

[B67FSTB]

Today I have to make another lower steering column seal plate. The one that "holds" the steeringcolumn at the lower part. Like the one that is supplied with a borgeson conversion kit. In that order. I had some zinc plted sheetmetal laying around.
Copied the orignal one and included the holding taps in the design. Just eyeballing of how the angel would be.
Took the jigsaw and clamped into the workmate.

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[B67FSTB]

Next was installing the steeringcolumn.First I had to center the input of the box by adding a washer between the frame and box. Once that was done, Man , that went in smooth !! Even clamping the lower part of the steering column is OK . All dimensions and gaps were , to me , 100%. Very, very pleased with my work.

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