I should probably wake this thread up from the dead!
I didn't make much progress over the summer, garage was basically 110° every day, not dealing with that.
Now that it's cooled off, I've started chipping away again. This week I've been trying to figure out the track bar. Surprisingly, this has been the most difficult thing so far to get right, but I think I've gotten it figured out now.
I wanted the track bar to be parallel to the drag link when steering straight ahead and at ride height to give me the best chance of not having bump steer. Due to packaging, it needs to be offset to the driver side a few inches. It of course needs to be equal in length to the drag link as well, which ended up being 38.5". Figuring out how to hold the bar in the exact right position while cycling the steering to check clearance was the difficult part.
Here is what I came up with:
Using two clamps and four sets of straight edges, and with the axle centered, at ride height, and steered straight, I attached the track bar to the drag link. Then, using two sets of levels and a block of wood, I set the two links level to each other. From there, I basically just eyeballed the side to side position, got the joint as far forward as I could to clear the coil spring, then built the bracket around it. It took a lot of trial and error, cutting and re-tacking pieces in place. All the clamps have to go when I want to test clearance and move the steering. Here is a shot from the front:
Probably would have been a bit easier if I had gotten a narrower joint, but in the end it worked out, at least I think so.
Here is the finished bracket tacked in. Full lock driver:
Clears just fine! Full passenger:
Can't ask for a tighter fit than that!
Clears the tire too, thankfully:
One issue though is that when the suspension compresses, the bolt head does interfere slightly. It just barely kisses the drag link at full steering stop, and I might be able to fix it with a thinner washer. The one in there is rather thick. If not, a hammer should suffice. This happens because the axle moves forward a little through the arc created by the control arms, but the steering box side of the drag link does not.
Here is what my steering looks like from the front at a little less than full bump:
Next task is to figure out the driver side of the track bar mount. Feels good to finally be making progress again!