Borgenson/Delphi power steering box install issue

[richg]

Attempting to install my new borgenson power steering conversion box (PN 800125), but am having an interference issue. The truck is a '73 and previously had factory power steering.

The mounting pattern does match, but it appears that the unused 4th mounting bolt is interfering with the weld fillet on the frame bracket.

Does everyone grind this off? I thought I was buying a "ready to go" box (the mounting points definitely were modified, you can see how they have re-drilled new mounting holes).

Any help would be greatly appreciated. Trying to get this knocked out today.

rich

 

[thegreatjustino]

With the way Bronco frames were welded at the factory, some things bolt on without issue, others need to be modified. Grind the weld or grind the box to gain the clearance you need.

 

[richg]

Got it, thx.

 

[SC74]

Bringing this to the top. I have a new Borgenson box. Couple of questions.... were the original bronco frames sleeved for the steering box bolts? My Bronco had some sort of Toyota box on it and the holes in the frame had been enlarged to line up. I'm not 100% sure where the factory holes landed. Even with the holes enlarged, I can only get 2 of the 3 bolts in the new Borgenson box - the right two. That is using the lower mounting hole on the bottom right as shown in the pic on the original post.
I can do some more enlarging to make the bottom left fit, but kind of concerned because I thought it was supposed to line up. Is it necessary to drill the 4th hole?
I'm considering plating both sides of the frame with some 1/8 or 3/16 just to beef it up a little.

 

[Timmy390]

The original frame had very weak frame inverts. It was "L" channel. Very easy to knock out.....I replaced mine with some 1/4 wall DOM when I installed my Borgenson box. I drilled my 4th hole because IMO more is better. That and I'm running 33's which is "what they say" is the upper limit on the Delphi box. I also welded plate on both sides of the frame for extra strength. I don't recall having to enlarge my holes but every Bronco is different.

Tim

 

[SC74]

The original frame had very weak frame inverts. It was "L" channel. Very easy to knock out.....I replaced mine with some 1/4 wall DOM when I installed my Borgenson box. I drilled my 4th hole because IMO more is better. That and I'm running 33's which is "what they say" is the upper limit on the Delphi box. I also welded plate on both sides of the frame for extra strength. I don't recall having to enlarge my holes but every Bronco is different.

Tim

Gotcha. So you overdrilled every hole to sleeve the existing three plus the 4th with DOM. I’m not opposed to doing this at all. Actually if I do that, it’ll be easy to get the holes just right. I just wanted to make sure I’m not the only one having fitment issues really.

 

[Timmy390]

No over drilling. I knocked out the frame inserts with a pry bar and hammer. I got to them from the frame horn/open end of the frame after removing the bumper. I then put in the new DOM spacers. The only drilling I had to do was the 4th hole....and the holes in the plate I welded on each side of the frame. I drilled the plate to match the frame mounting holes.

Tim