Seems there are three popular choices……….IH Scout, Range Rover P38, or Toyota FJ. I initially went with the P38 steering gear, but felt it was just too big (vertically it takes quite a bite out of the inner fender) Scout boxes are getting hard to find, so I went on the hunt for an FJ60 gear (on the advice of Jim Young / Series Trek). I found one at a wrecking yard in New Hampshire. Pretty ugly on the outside, but once opened it was in nice shape internally.
Holes bored in the frame. Backing plate with two grade 8 studs welded up. The plate will add some strength to the frame where the steering gear mounts.
Guide tubes will be welded into the frame.
Plate in place and clamped firmly so it doesn’t shift during welding.
Welded in place
Steering gear in place.
Worm gear cut off Series 2 shaft. A length of steering shaft from Borgeson turned down on a lathe and inserted into the stock shaft. These will be tig welded together.
The Borgeson shaft and Series 2 shaft prepped, beveled and ready to weld.
The bearing carrier, which mimics the part used by Pangolin 4×4 in their conversions (first seen on their “Pabst Blue Rover”), made with pressed in bronze bearing will mount to the modified bulkhead support. This will support the modified steering shaft inside the stock steering column.
Carrier and steering shaft in position.
Borgeson to the rescue once again with two universals and collapsable “cut to fit” steering shaft.
The stock Defender reservoir is used along with the power steering pump located under the alternator. I had a local heavy truck dealer make up the lines for me.