One of the project trucks here at Custom Classic Trucks that we've recently inherited from our now-defunct sister publication Kit Car is Eric Geisert's California Hauler '41 Willys pickup. I've been helping Eric sort out a number of items on the project including mounting the Smeding-built small-block Ford drivetrain as well as mounting the cab and related components. The foundation of the Willys is an '82-95 S-10 chassis that has been modified to accept the Ford drivetrain and Willys' fiberglass body and fenders. The stock GM suspension was kept intact but the stock S-10 steering box and cross-steer components proved to be too cumbersome for the new setup and were deleted in favor of a new steering system.
Enter Unisteer Performance Products and their rack-and-pinion retrofit kit available for the aforementioned S-10 family. It consists of a new manual rack-and-pinion as well as the necessary universal joints, available in a number of configurations, to mate it to any aftermarket steering column. For that end, we opted to go with a LimeWorks Hot Rod steering column in raw stainless steel to mate to the Unisteer rack. We figured out the length we'd need for the Willys' column and gave the measurements to LimeWorks while the column drop and floor mount requirements were handed over to Borgeson Universal. With parts in hand, we set out mating the components together to provide a bulletproof combination that will work flawlessly while maintaining an early hot rod vibe that will complement the rest of the build.
As a one-off setup, our steering system is most likely more complex than what most builders will be confronted by. But with the rise in availability of custom rack-and-pinion units designed to replace stock side-steer boxes and the popularity of retrofitting stock columns with tilt versions, we thought this how-to example would solve a number of questions the first time steerer-setter-upper would confront.
With the help of the aftermarket industry, we tore off with parts in hand and within an afternoon had the steering in the Willys dialed in, allowing us to move it about the shop with ease. It not only freed us from the confines of the stock S-10 box, which would have contributed to a myriad of problems due to the small-block Ford engine choice, but it also gave the Willys the improved steering characteristics related to a modern rack-and-pinion design. Take a look, take notes, and let us know how your steering relegations in your custom or classic truck take shape.
Once the angle of the steering...
Once the angle of the steering column is determined, the first step is to drill a 13/4-inch hole in the firewall of the cab. This serves as the lower mounting point for the column and where it will exit cab.
Next, we fabbed a bracket...
Next, we fabbed a bracket to serve as the mounting point for the Mullins 3-inch column drop.
We used a portion of 13/4-inch...
We used a portion of 13/4-inch tubing as a column mock-up to find the angle desired before drilling the hole in the firewall and to determine the amount of column drop desired. From there, we took a measurement to find the length of column we needed.
A Mullins swivel floor mount...
A Mullins swivel floor mount will hold the base of the column in place against the firewall.
LimeWorks fabricated a 13/4x221/2-inch...
LimeWorks fabricated a 13/4x221/2-inch stainless steel Hot Rod steering column to suit our custom needs. A mock-up steering wheel is in place for the time being.
The business end of the steering...
The business end of the steering column juts out from the firewall just enough to mate to a 3/4-36 U-joint. Note the clearance machined into the shaft; more on that in a bit.
As we mentioned before, the...
As we mentioned before, the Willys' foundation is a stock S-10 chassis ('82-95)...
...and since we're going to...
...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...
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,...
With our rack and column installed, it's now time to start mating the two steering components.
We're using Unisteer universal...
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...
At the column, a 3/4-36x3/4DD U-joint is...
...used while the rack receives...
...used while the rack receives a 9/16-26x3/4DD U-joint.
Since we're utilizing a three...
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...
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...
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...
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...
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...
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...
...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...
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...
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.