Cutting a steering rack ?

[AJKOK1]

Hiya,

My Westfield kit advises that as i have the larger front track option, i need to cut 15mm off each of the threaded ends of my rack and then add the extension pieces provided.

I am nervous at cutting them as 15mm is part way down the threaded ends of the rack and i need the remaining thread to still be operable.

Is a patient hacksaw job the simplest and safest way to do this ??

[Russ Bost]

Run a couple of nuts up the thread past the section where you want to cut, then either hacksaw or use 1mm (or similar)" superthin disc on an angry grinder & remove the section you don't want. Carefully file around the end of the thread making sure there is a "lead" left for the nut to engage with when putting back on, taper the end of the "lead" slightly with a file. Now remove one of the nuts working it up & down over the end of the cut thread whilst removing, don't remove until it completely until it feels a comfortable fit over the end of the thread. Once removed ensure you can easily engage & refit before removing the other nut - if you can't refit do NOT remove the second nut until you've got the thread sorted.

[hal 1]

If you're worried that there might not be enough thread left to use, then use a die to take the thread farther down the track rod, i've done this myself when i altered the rack on a car i had.

[Mr2Mike]

You can't use a die to extend the threads on most track rods as the original threads are usually rolled rather than cut, so the diameter of the unthreaded portion is not large enough to cut a correctly formed thread in.

If you are simply worried about causing damage to the end of the thread then there is no need, and you don't need to thread nuts on first (though it won't hurt). Simply cut the track rod to the required length, then use a sharp hand file to clean up the cut and and file a nice even taper around the end to give a suitable lead-in on the first thread. I have cut down hundreds of fasteners like this and never had a problem getting a nut to catch easily.

[AJKOK1]

Thank you all for your suggestions. Mission accomplished.