Power Steering Adapted From A 91 Chevy S-10

First, let me state, this is not the easiest conversion. I had a few very strict goals I wanted to accomplish when I one this conversion, and it follows along with some of my other mods to my rig.

GOALS FOR THIS PROJECT

1. Use as many common of the shelf parts as possible, from as few different vehicles as possible.

2. Make as little or no modification to the normal wear/replacement parts. This will make service on the trail or even in the shop easier. The parts should be able to be installed with common hand tools, no cutting, welding, or other heavy mods to the parts.

3. Be as cheap as possible to do.

Sounds easy enough. On with the install.

Since it was raining and wet when I decided to start the conversion, and my shop was full of customer vehicles waiting on parts, the first thing I done was make three slugs to weld into the frame rail for mounting point on the steering box. These were a simple job on the lathe, just some cold rolled round stock, turned to an OD of 1 inch, with a bore thru them of 7/16inch, and faced of 3.75inches long. These will weld to the frame rail, and allow me the factory steering box bolts.

Then it was on to make a power steering pulley. I decided to make a pulley  after studying some other systems, and looking at the stock GM system I was going to be installing. All the power steering parts came from a 91 Chevy S-10 pickup with a 4.3L V6 and automatic transmission. After deciding the parts will fit, one way or another, it was time to figure how to make them work on the Samurai. First thing I decided was the pulley was going to have to be the same diameter or smaller than the 1.3L crank pulley. the stock GM crank pulley was 8" diameter, and the P/S pulley was 6.5" diameter. Using the 6.5" pulley on the stock 1.3L crank pulley groove which is 4" diameter just will not spin the pump fast enough to make it work right.

I cheated just slightly in making the pulley. The stock GM pulleys are two pieces, the center hub comes right out in a press. Without a press you could heat the center to release the brazing and knock it out with a hammer, but it may distort the press fit to the pump shaft it needs.

After removing the center and cleaning it up a little in the lathe, I started on the pulley.  The pulley started life as a block of steel roughly 5"x6"x1"thick. I have no idea what type of steel it is, it came from the scrap box. It has been there for a good 6 months or so and has not rusted so that may be a clue.