Chris, did you ever send the file to Ken? Dave H. wants to convert his rack. I did print out the file, before you dumped the web site, so I can scan that and send it to him if necessary.
By the way, I did your mod and had no problem with it. It was a GREAT step by step guide and the pics added to the clarity.
On one of my racks, I did two, the rack turned easily when I put the gears back into the housing but it binds up when I put the shims and such on as part of the final assembly. I have no idea why it is binding unless I have some of the parts in the wrong order or something. It works like a dream until the final step. Any ideas of what to look at. I was afraid to simply leave out a shim for fear it could do something bad, in the future, to the rack and did not want to go into a tight hairpin from 200+ and have the steering lock up.
Big Dog