Wooo Hoooo! I finally have Killer back on the road. It has been a long time, but well worth the effort. While I had it down I not only installed my own rack conversion, but I also added hydroboost, a new clutch, and a couple dozen other little things.

Here is the skinny on the rack. I have to do things my own way and I get a rush out of building things on a tight budget (often none at all).

Parts for my conversion:

1. 1992-98 G/A Rack (used)
2. a pair of passenger side 92-98 G/A tie rods
3. 12"x4"x1/4" angle iron
4. 12"x2"x1/4" angle iron
5. 12"x1"x1/4" flat iron
6. Misc nuts/bolts/washers
7. Tape measure
8. String
9. stock hoses to fit a 1983 1 ton chevy truck (I also tied the rack into a hydro-boost).
10. late model malibu universal shaft

total cost = < $150

After removing the stock system I test fit the bare rack by clamping the 4" angle iron to the driver rail where the stock gear box goes. I used string from the motor mounts to figure the drop down position and centered the rack directly under the motor mount pods. During this process you have to pay attention to the "clocking" angle of the rack in relation to where the input steering shaft will attach. I also removed some materal from under the motor mount to frame location to make sure there would be ample room for the steering shaft coupler to mount and spin. After a position was determined I fabricated the permanent mounting brackets. Next I located the center position and fabricated a plate to mount to the rack then offset the tie rods left and right. The G/A tie rods are just a tad too short to hook right to the stock position on the rack. The center bracket not only allowed me to center them to the Corvette, but to get the extra length needed to reach. I was able to use a pair of passenger side tie rods from the G/A (fits like they were made for the car) which dropped right into the Vette spindle knuckles. The late model malibu universal shaft slides in and out. It only has two U-joints compared to the three that is more common on this conversion. They work together perfectly to reach the column. I ground a D on the column shaft to allow the malibu joint to slip on and clamp down. I did grind a slight taper to the lower portion of the upper joint to give more room on the header. I also had to dimple in the header pipe a tad for more space.

There are a variety of good technical discussions on exact position of the inner tie rods for perfect bump-steer elimination. I have looked at them and measured from them. However, I have found that using the stock G/A rods not only saves a ton of money and time, the lack of bumpsteer (compared to the stock design) is incredible. I don't have the exact measure, but WOW...the car is so stable and smooth on any kind of road surface it will blow your mind. I will never road race this car, and am not concerned about reaching extremes on the final run-out of the bumpsteer issue. These ultra long tie rods seem to balance out the pivot across the spectrum. For spirited street driving, you can't beat this design. After 200 miles...I am very pleased.

A huge thanks to evalu8r, twin turbo, norvalwilhelm, mrvette, 427V8, and many others who offered advice and the "been there...done that" help that made this all possible.

I detailed with photos here:

http://mcspeed.homestead.com/Rackinstall.html

 

Chris - You are truly an inspiration for all of us (or just insane). I stumbled across "killer" a couple of days ago and had to post the story. I was not aware you were a forum member. Let me know when you want to drive a couple of hours north to help with my '68.



http://forums.corvetteforum.com/show....php?t=1386658

 

u did all this on ramps? my neck is getting tired just thinking about it. Nice job!

 

looks good, are you planning to add a heim joint on the double d shaft or is that not necessary on your design?

 

Don't need it. The malibu has a heim that goes right on the rack, and the other end with minor grinding on the shaft fits like a glove.


This has really been a fun mod. I do have to mention though that I would suggest anybody do this that is not 100% comfortable with cutting, welding, etc.

If you consider the hours I have in this at $10 a hour, I would have come out way ahead by just installing a Steeroid system.


I did the install while the car was up on jacks.



Sperkins...Yes... I am insane... but aren't we all from time to time? Thanks for checking out my site.

 

Glad it worked out 69MyWay and thank you for including me in the thank yous but I was one of the doughters. I spoke against the swap.
You do really nice work, your car is fantastic and you do document eveerything for others to follow.
Very nice job and I am glad it worked for you.
I am also glad the hydroboost worked out well and I read your impressions of it already.
What's next of the agenda?

 

I know you prefer the Jeep box. I like that idea as well, however one huge goal I had was clearing more space under the hood and that included removal of the old gear box. Going to the Jeep box would have gotten rid of the Vette style steering, but would not have improved my space issues.

Your tie rod discussions are great and the pursuit of zero bumpsteer is clearly an area you have had success with.

Next? Other than getting the cruise control on-line (Audiovox aftermarket unit tied to a OEM column switch and hidden) and some minor tweaks...I am very satisfied right now.

There may be..hint...hint..some cool caliper/rotor mods coming in the future...cough...C6...cough........

Oh...and a Zex go juice unit...cough...cough.......


But, nothing really.

Or...if somebody wants to make me a sweet offer, I could always let her go to another garage to live while I dream up new projects.

 

Awsome Hope my response is the same as yours. Should be couple more days.

Chris

 

You are going to love this modification.

You will also want to slap a hydro-boost on there too, if not already in the plans. It is simply shocking what a difference that makes.

 

Excellent job. Well done. My home built system is working out great also. Nice and smooth. Driving at 70 mph on a bumpy road is not a white knuckle experience anymore.