On the positive side, I’m finally seeing light at the end of the tunnel when it comes to the SN-95 five-lug conversion of the Great Pumpkin, our 1980 Ford Mustang Ghia. The rear axle is installed, and that went beautifully. The steering rack is in, but there was one little, teeny-tiny tidbit that I didn’t notice at first. Something I should’ve paid attention to when I disassembled the 1994 Mustang that I raided for the parts, something that was threatening to throw a huge wrench into my plans: the connection between the steering wheel and the input shaft of the rack and pinion. Doesn’t seem that problematic, does it? Just slide the steering shaft over the input shaft, tighten and move along. Not so fast, chief.
The top photo represents the 1979-93 Fox Mustang rack and pinion. That setup is round and splined. The bottom picture is the SN-95/New Edge rack input shaft, which uses a “V”-like shape. Obviously, the Mustang’s steering shaft was not going to work as it was…and I didn’t keep the shaft from the 1994. Given that the Ghia will see an engine swap with headers in the future, putting a rag joint back into the car wasn’t that appealing either, and of course I find out all of this just as the whole world come screeching to a halt. Fun.
This is where working with good companies comes in handy. We reached out to Borgeson Universal Company to see if they had any ideas about mating Fox Body and SN-95 pieces together. Happily, they did…kind of. If you were just redoing the shaft in a Fox or SN, you’d order the proper shaft and it’d show up completed, u-joints at both ends, ready to install. Since I’m running a hybrid system. I would be building my steering shaft from pieces. It’s not that bad…in fact, if it wasn’t for needing a better cutting system than what I have in the shop, this would’ve been an in-home project that would’ve taken maybe a couple of hours total time. Follow along as I show you just how straightforward this is: