1941 Willys Pickup Steering System Setup - Turning Point

As we mentioned before, the Willys' foundation is a stock S-10 chassis ('82-95)...

...and since we're going to drop in a small-block Ford V-8, the stock steering box and related bits will need to be removed.

Unisteer manufactures a brand new rack-and-pinion kit that bolts into the stock mounting point for the idler arm on the passenger side and the steering box on the driver side. A few clearance issues are involved but nothing a plasma cutter can't handle.

With our rack and column installed, it's now time to start mating the two steering components.

We're using Unisteer universal joints in a three-joint system to mate the column to the rack.

At the column, a 3/4-36x3/4DD U-joint is...

...used while the rack receives a 9/16-26x3/4DD U-joint.

Since we're utilizing a three U-joint setup, it's a matter of careful measuring along with a bit of know-how to get the first length of DD shaft cut to the correct length. Here, the clearance for the pinch bolt is being machined into the curved edge of the DD shaft.

This is where the machined area comes into play. The pinch bolt of the U-joint slides through the machined area and once fastened, locks the shaft into place, ensuring that the shaft cannot slide out.

Here's the shaft mated to the column-side U-joint. Note the relation of the shaft to the U-joint. It should be flush with the inside edge to allow the U-joint to articulate without hindrance.

One of the requirements of a three-joint system is the use of a support bearing. This prevents the steering system from binding and supports the upper shaft just before the middle U-joint.

We fabricated a riser for the support bearing to thread into that will allow the bearing to be adjustable in height. It's tacked while we fit the rest of the steering components but will be fully welded along with a gusset plate once complete.

Once the upper shaft is trimmed to where it's in line with the rack U-joint, a 3/4DDx3/4DD U-joint is installed and the distance is measured between the two...

...before a corresponding length of 3/4DD shaft is cut to fit and machined for the U-joint pinch bolts.

Here's what the steering system looks like with everything installed and snugged up. It clears the headers with plenty of room for removal and is free of any joint bind.

Inside the cab, a LimeWorks 4-spoke drilled steering wheel is installed atop the column and the Willys' dash is reinstalled to complete the steering installation.