UPDATE: Sam has provided some detailed instructions (which will replace mine) and will also be sending some pics when he completes his next installation.
One idea Sam has shared with eWillys readers was the rack and pinion steering modification he has been doing. He describes this as a pretty straight forward installation that can replace the stock steering in any flattie. Sam says this takes him about four hours to complete. Pics are forthcoming on this modification.
Sam describes the process as follows:
1) Remove Steering: Take out the existing steering mechanism and the mounting plate.
2) Remove Drag Link: Remove drag link from old box to bell crank
3) Layout Straight Edge: With front wheels straight ahead, use a straight edge (anything will do, I use a piece of conduit) and lay one end on the passenger side tie rod from the spindle and the other side on the frame rail directly above the drivers side tie rod end at the spindle This will give you the approximate location for the rack and pinion. DO NOT USE original box location as this will put the cross link through the engine block.
4) Where to Mount Vega Plate: Take the Vega box mounting plate (The plate Sam uses is this plate from Unisteer.com) and using a large C-clamp, attach to frame with the top of the plate even with the top of the frame. This will put the mounting holes in the right place. You will notice the top two holes are inside the opening of the frame and the third hole is below the frame as it should be.
5) Temporarily Mount Rack: The rear edge of the Vega plate should be ONE inch ahead of the line from the tie rods towards the front of the vehicle. NOTE….at this point, it is very important to temporarily mount the rack (You may use longer bolts to clear the C-clamp). Once mounted, move the wheels all the way to the right and make sure you have at least one inch clearance between the cross link from the Rack and the oil pan. Do the same with turning the wheels to the left. If you have the proper clearance, you have the right location for the mounting plate for the Rack and Pinion.
6) Weld Plate to Frame: Weld the Vega plate in place and be sure to use the supplied gusset ( I use two of them, as I have found that with one gusset, there is a chance for mount twist under harsh conditions such as four-wheeling……strongly suggest you do the same grin grin)
7) Attach Rack and Pinion: Bolt the Rack and Pinion in place and attach the cross link to the Rack and with the Rack centered and the wheels dead ahead, mark the cross shaft for cutting allowing for the length of the tie rod end. Now you may cut, thread, and install the tie rod. The unit Sam uses is this cross steer rack from unisteer.com (that link is dead, but this may be the one). 
8) Determine Steering Rod Length: Using the conduit, determine the route from the bottom of your steering column to the Rack and Pinion. This varies with engine and frame variations but is very simple. Usually all that is required is to determine if the column needs to be shortened or if a double joint is needed. At this stage, determine what your shaft is…..splined, D shape, square, etc. This will determine which joint to use. If round, (with roll pins) I strongly suggest you modify it to D-shape for strength. Sometimes you have to use TWO rods from the column to the box. If so, USE ROD SUPPORTS before and after middle joint. You can get everything you need from Borgson Joints. If you choose the shorten your column (to use One Rod) you can can get the necessary seal and bearing from them too.
9) Double Check Everything: Double check everything for tightness and clearance and YOU ARE DONE — smile, have a beer.
This sounds simple and it really is, I’ve done soooo many of them, that I can do it start to finish in four hours. If anyone still needs help, just call me or Dave and I’ll be more than happy to walk you through it. The last one I did cost $612.42 for everything, Somewhat cheaper than regular boxes and a whole lot better looking and steering.
If properly installed, you’ll notice the steering much tighter while driving and capable of easily turning under the weight of even a V8 when parked.
Dave…… Glad to see this on the sight but one very important correction needs to be done, Here is the steps to take for a 4 hour conversion……..Step 1…..remove old steering box Step two….remove drag link from old box to bell crank Step three……with front wheels straight ahead, use a straight edge (anything will do, I use a piece of conduit) and lay one end on the passenger side tie rod from the spindle and the other side on the frame rail directly above the drivers side tie rod end at the spindle This will give you the approximate location for the rack and pinion. DO NOT USE original box location as this will put the cross link through the engine block—–grin grin. Step four……take the Vega box mounting plate and using a large C-clamp, attach to frame with the top of the plate even with the top of the frame. This wll put the mounting holes in the right place. You will notice the top two holes are inside the opening of the frame and the third hole is below the frame as it should be. Step five……The rear edge of the Vega plate should be ONE inch ahead of the line from the tie rods towards the front of the vehicle. NOTE….at this point, it is very important to temporarily mount the rack (you may use longer bolts to clear the C-clamp). Once mounted, move the wheels all the way to the right and make sure you have at least one inch clearance between the cross link from the Rack and the oil pan. Do the same with turning the wheels to the left. If you have the proper clearance, you have the right location for the mounting plate for the Rack and Pinion. Step six….weld the Vega plate in place and be sure to use the supplied gusset ( I use two of them, as I have found that with one gusset, there is a chance for mount twist under harsh conditions such as four-wheeling……strongly suggest you do the same grin grin). Step seven…bolt the Rack and Pinion in place and attach the cross link to the Rack and with the Rack centered and the wheels dead ahead, mark the cross shaft for cutting allowing for the lenght of the tie rod end. Now you may cut, thread, and install the tie rod. Step eight….using the conduit, determine the route from the bottom of your steering column to the Rack and Pinion. This varies with engine and frame variations but is very simple. Usually all that is required is to determine if the column needs to be shortened or if a double joint is needed. At this stage, determine what your shaft is…..splined, D shape, square, etc. This will determine which joint to use. If round, (with roll pins) I strongly suggest you modify it to D-shape for strengh. Sometimes you have to use TWO rods from the column to the box. If so, USE ROD SUPPORTS before and after middle joint. You can get everything you need from Borgson Joints. If you choose the shorten your column (to use One Rod) you can can get the neccessary seal and bearing from them too. Step Nine Double check everything for tightness and clearance and YOU ARE DONE>>>smile, have a beer. This sounds simple and it really is, I’ve done soo many of them, that I can do it start to finish in four hours. If anyone still needs help, just call me or Dave and I’ll be more than happy to walk you through it. The last one I did cost $612.42 for everything, Somewhat cheaper than regular boxes and a whole lot better looking and steering.
Do you have any contact information for Sam? Looks like it might provide a better option than the Toyota Power steering I’m considering for my FC.
Thanks Dennis
I live in Wheat Ridge….right next to Arvada. I’d like to chat with Sam too. Contact info. would be great. Thanks,
Bob
You bet Bob … You can contact Sam at 720-841-0614.
Talked to Sam yesterday Wow! what a wealth of knowledge. As soon as I can sneak out of the office I’m going to go up and see him.
Dave,
Thanks for the contact information.
Dennis
I did a search for rack and pinion steering for a Willys planar suspension and found your site. Can you clarify for me that the Unisteer cross-steering rack can be installed on a wagon with the stock planar suspension? Any help on finding an information source for this would be greatly appreciated. Thanks very much.
Hi Jim,
The best I can do is recommend you contact Sam at his new place of business: http://www.yellowpages.com/chino-valley-az/mip/motor-pool-480867337 This was his project. After he moved, he stopped pursuing it. However, he may still have some useful information.
– Dave
Can you help me with rack an pinion conversion for 42gpw.i have fitted pinto engine. And would like to improve steering. I also have disc brake conversion kits available for sale all bolt on. Alex boes Australia. 0412 819 747.
How do you make the uni steer work on front steer with the direction issues
I wish I had more info, but Sam is the guy who was worked on this project. But, I haven’t heard anything from Sam in a couple years. Only he can answer your questions on this. I wish I had more info,
– Dave
What are the part number for unisteer cross steer rack and pinion I should use for this install?
Hi Ken,
Unfortunately, I have no contact info for Sam, so I don’t have an answer for you.
– Dave
Please respond
I have a 2004 GC. I’ve changed out the steering gearbox with remanufactured boxes at least three times and I just hate it’s road feel, constantly adjusting and I hate it. I found a steering rack from a 2005 GC ( grand cherokee) and was considering it. There’s nothing out here on the interwebs about this conversion or any other box to rack conversions, your post is as close as it gets. I figure this info would be good for xj and xk owners too with all the death wobble talk and lifts ruining tire geometry. Please advice.
Hi Mark,
I haven’t heard from Sam in years and don’t have any other specifics on this modification (or how it has held up over the years). So, unfortunately, I’m of no help with this topic.
– Dave
The link for the R and P is a dead link. Does anyone know what the part number is?
Hi Dave,
Yes, I need to update that. R&P went out of business. It’s now being run by one of the original owners, Rich. I’ll see if I can locate his address.
– Dave
Hi Dave,
Oops, I thought you meant R&P Jeep parts, which as gone out of business, but I see now you meant the Rack and Pinion link. Based on the pics, I think this might be the one: https://www.speedwaymotors.com/Unisteer-1928-32-Ford-Cross-Steer-Rack-and-Pinion,2033.html .. unfortunately, I have no heard from Sam in years, so I can’t verify it. I also have not receive an update on how well this system has worked on a jeep.
– Dave