Manual Steering!
Big progress again tonight.
Finished assembing the modified rack.
Removed the power steering rack, pump, lines, cooler etc.
Mounted the idler pulley (Dayco p/n 89028 - thanks Kyle for reminding me of the application) by drilling out the middle ps pump mount hole. I still need to machine up a real spacer and get a longer bolt, but otherwise thats done. The tensioner ended up in almost the exact right spot, according to the pointer and marker on the two halves.
Installed the new rack, completly torqued etc.
I weighed everything quickly and it looks like the swap removed about 13-15lbs, not bad.
Dan