Poer steering assembly issues
 

Tonight I decided to install the Boss Frog power steering kit on the Miata rack. As you know, the goal is to replace these steel lines with braided flexible lines.

Attachment 7005

Things do not fit as well as I would like them to. First, this small fitting hits the raised boss for the return line. Probably not that big of a deal. I can trim the boss a little with a die grinder.

Attachment 7006

Then, once that fitting is installed, the larger fitting for the return line hit's the smaller fitting, so it can't be tightened. I'd have to trim that fitting as well.

Attachment 7007

Since it's a low pressure return hose, I think I'll use the stock hard line instead.

And, finally, the banjo fitting is too thick. I need to either buy another banjo bolt, or buy another adapter fitting that's thinner.

Attachment 7008

Not a well designed kit, and (IMO) certainly not worth the money.

In reading threads around de-powering the rack, it was mentioned that there are several different power racks that were used over the years. It may be the kit was based on one version and you have another. Still makes for a sub par experience...

Hate to say this but Flyin Miatas V8 power steering kit was the same deal. I ended up using one fitting out of it and it was by far the worst 100 bucks I ever spent on the build. Actually now that I think about it as my clutch lines are leading at the slave the $200 clutch kit was pretty pointless too.

First problem solved easily enough. A few minutes and a die grinder allowed the smaller fitting to seat properly. Before grinding, I stuffed the ports with paper towel bits, and then blew them clean.

I could have also modified the larger fitting by cutting off the corners, or making the flats smaller. But I think I'm going to use rubber hose and clamps anyway, so no big deal. If I decide to use AN fittings, I can always change that.

Attachment 6982

Attachment 6983

I still have not solved the banjo bolt problem. I can find plenty of bolts for brake systems. But nothing specifically for the P/S system. The difference appears to be the size of the holes. I'll pick up a Dorman's bolt from Autozone, and then try to drill the holes bigger.

I visited with FM earlier this month. I picked up a bunch of parts. And they let me take a close look at the XXXocet. As you may already know, the instructions that come with the kit are... well... nonexistant. So I had a chance to take a very close look at their car, and see how things go together.

I took this picture.
Attachment 6935

As you can see, the only AN line they used goes from the pump to the rack. The rest are stock lines. I'll be doing the same thing.

I was kind of wondering what was deficient in the stock lines to want to go braided.

Well, I was doing a lot of reading (too much reading?) and kept hearing about an interference problem between the oil pan and PS lines. Boss Frog sells the kit. I picked it up second hand half price about 6-8 months ago.

Live and learn.

off topic---
You bought the clutch kit(http://www.v8roadsters.com/lsx-clutch-kit-1/) from FM and saying it was just about useless?
care to go into detail?

Well that was poorly worded and really not fair. The PS kit deal was I was using F body parts and the FM kit is for vette stuff. That was a lesson learned the hard way... The clutch is fine but you can get the same parts off your Summit and use some of your donor car stuff for a whole lot less money.

The thing with FM kits is they all work around their builds. So if you use the parts they use they are great but if you use a donor you may end up with a $100 fitting that would have cost 5 bucks...

Having built & maintained an LSX Miata for several years now & without a kit, can say that there will always be a need to massage parts, regardless of their source. There are simply too many differences & variables build to build to expect otherwise. Best advice is to lay out & pre-measure (study) the work area & then compare it to what you plan to purchase.

Save any unused parts. They may be needed sometime in the cars' future.