As expected, I ran into some issues installing the new rack. Specifically, the housing OD is larger than and the section where the steering shaft connects protrudes lower than the stock rack. Compounding this, my chromoly tube frame prevents the rack from sliding upwards. To get it to fit, I had to scallop the top of the extended foot box and enlarge the opening in the vertical face of the monocoque. I’ll add a close out panel when the rack’s location is finalized. Most builders don’t have a nose frame, so I assume they won’t need to scallop the top of the extended foot box.
The pillow block holes were sized for M6 bolts and at Agile’s suggestion I enlarged the holes to M8 (future pillow blocks will be predrilled). I was hoping to reuse the stock rack’s top mounting holes in the monocoque, but that would result in a loose fit. So, all four holes will be welded shut and re-drilled. I don’t have the tie rods yet and I want to check bump steer before I finalize the mounting.
To keep the bellows from rubbing the monocoque, 1/4” spacers are needed. I fabricated some temporary ones and I’ve asked Agile if the manufacturer can provide pillow blocks that are 1/4” taller. The factory ships the car with washers and nylocs on the backside of the pillow blocks. I added backing plates out of 1/8" steel.
Once the rack was in place I was able to determine where to locate and weld the crossbar on the top of the nose frame in front of the foot box. Due to ongoing changes, the Penske shock reservoirs have been kicked out of every location they’ve had and the crossbar provided an ideal place to mount them with some trick brackets from Joe’s Racing. Pull the pin and it pops open. Push the cam down, replace the pin and it’s locked. A simple design that works really well.
