I've installed the manual rack in place of the original power steering rack. I thought it was just a bolt-in until I tried to attach the relay shaft. The relay shaft mount bolts to a bracket in the middle of the steering rack. Well it turns out that the bracket was not the same as the bracket from the original Power rack. The manual rack was salvaged from an early 80's diesel Rabbit and the only thing I can figure is perhaps it was a 4 speed rather than 5 or maybe its not the 020 transmission. I asked Paul if he had a similar issue but he said that his bolted right up. Anyway I had the relay shaft mount welded to the bracket on the rack. It looks like it will work out OK but the truth will come when have the NetGain Impulse 9 and transmission back in the car. I put on new tie rod assemblies and boots. I still have the outer ends to install but I am going to first replace the springs and shocks from the front struts.
I tried removing the left side inner fender liner to get at one of the last few remaining ICE components on the car but it was being uncooperative and I didn't want to risk breaking something in the process. On this Cabriolet, some of the fuel vapor recovery system, like the charcoal canister hide in the inner front fenders. If I must have the additional weight savings I will tackle the project again.
When I had removed the gas tank I noticed that the rear brake hoses were showing signs of nearly 20 years of age so I replaced those with new ones bought at AutohausAZ.
I constructed my template for the rear battery box and marked it on the floor of the trunk. My width marking on the floor is about 1/8" long so I'll cut it a little short. I get to make another tool run to pick up a few metal blades for my reciprocating saw and a some grinder cutting wheels, also need a 22mm deep offset box end wrench too loosen the nuts at the top of the struts. Oh well, no one said this was going to be a cheap project.
