- already have aftermarket blocks, specifically because I had a power steering leak that ate some bushings.... Just because I have reduced the effect of a leak on that particular area of my car does not preclude a leak from happening again. It will, at some point, leak again. Pressurized fluid seals will leak - those bastards!
- power/underdrive pulleys, while helpful for reducing (not eliminating) the parasitic loss, have their own problems, and I would question their long-term effect. I know people run them for thousands of miles, but I'm not sold. Sure- on a $750 Honda motor- sign me up as they are cheap to maintain and rebuild. Not so much on a 968 3.0.
- I wouldn't be reinventing the wheel going manual- the manual parts are Porsche parts which bolt directly in with no modification.... Doesn't get much easier than plug and play, baby!
- In my driving routine, even accessing my garage/driveway/etc., I can't ever recall needing to rotate the wheel completely lock to lock, hell, I don't think I have ever done one complete 360 degree turn..... And not knowing the exact ratio on the manual, I doubt that the extra 1/2 turn or whatever it might be to accomplish lock-to-lock will be seen in said routine.... And if it is, the one or two times I might have the need to explore said lock-to-lock turn count, I'm sure I'll cope!
- Yes- PS has been around a LONG time, and coincedentally, manual rack and pinion appears to have been around a hell of a lot longer
- Yes- PS may not be chronically problematic on other cars, but, IIRC, we're discussing the 968 here.... And PS on the 968 is notoriously problematic for leaks and pumps and racks that go bad (even rebuilt ones are no guarantee- ask Anchor about his wonderful experience regarding power steering racks in the 968.... nothing like not being able to turn in one direction while driving during rush hour!)
- Solving the resevoir design- sounds like custom work to me. Just like you, my time is money that I don't wish to spend reinventing the wheel.
So let's tally this up:
1) Power / Underdrive pully to reduce (not eliminate) parasitic loss on engine - cost of part, cost of new belt (?- don't know if you need a different belt or not), cost to install. I don't have one, so I can't comment, but I'll wager a guess and say that a minimum of $250 all tolled since this is a Porsche nonetheless!
2) Aftermarket blocks to eliminate the "eating" of bushings by potential leaks - had this done - cost of parts and cost of labor. I can go back and look, but I'll guess for now and say $300 or less installed. And handling is subjective- many people would probably like to keep OEM bushings because they like the feel. To each their own. I like them because they look trick and they are inherently better by design when compared to the OEM.
3) The need to replace fluid, lines, pump, belt, rack- we will all have to do it, some sooner than later. I think rebuilt racks can be had for under $200. Rebuilt pump probably less than $90. I dunno... Total would depend on what happened. I only had to have a line replaced. Cheap. Anchor had to replace his rack, IIRC.
4) Redesign the fluid system (new resevoir design, not sure what you have in mind, but I am sure it would be the cat's ass)- I don't even want to wager a guess on what this would cost for the prototype. I sure resultant cost would be in line with all the other excellent products. Not grossly expensive, but not Honda cheap either.
When all that is said and done- you still have a hydraulic system that will fail again. And to maintain said system, I can see where the cost to do so would eventually approach the cost of a manual rack kit install right off the bat or come awfully close on the first shot.
I just about pissed myself laughing when you used the razor on this one! Your view of the razor in this example just doesn't make sense- At best, to fix (and not forever mind you) or upgrade the PS shortfalls of the 968, one must further modify their car with a power pulley, upgraded bushings or castor blocks, then replace hoses and belts, rebuild racks, replace fluids, etc. when time dictates. Forget about custom engineering a new fluid handling system- that is beyond most 968 owners' desires. And all this does not eliminate leaks and it does not eliminate the chance for your rack to simply fail. I found out yesterday that the PS rack has a equalizing valve inside which acts to counterbalance the pressure from one side to the other during turning- that sucker can and will probably stick or fail- hence, you might find yourself not being able to turn in one direction. Not something I want to encounter at any stage of my driving experience.
Therefore, if you boil it down, the simplest thing to do would be to replace the problematic and complicated hydraulic system with a drop in mechanical system. Problem solved- basically forever. You save weight, you eliminate parasitic loss (which increases engine efficiency thereby increase actual RWHP and MPG), and you never have to worry about any leaks or needing expensive rebuilt hydraulic components. Just think of the $10 to $30 in gas per year that you will save!
The only potential downsides I see are:
1) Slow speed turning. Lock-to-lock doesn't factor in because it's not something one needs to do at the spur of the moment- furthermore, we don't know what the ratio is on the manual rack. It may be moot....
2) Mechanical wear on the intermediate shaft U joints. You'll get this eventually on the PS shaft as well... so moot for me.
It's clear to me, upon weighing all the current and potential issues and features that the truly simplest path is a manual rack.
And I'd be one step closer to being green by eliminating the toxic PS fluid and increasing my engine's efficiency . Al Gore will love me, and would probably invite me to his 25,000sqft house to join in on a game of mattress tag with him and Tipper! Ahhh Tipper! Now that is a woman you could cuddle up with and nuzzle as if you were a little grizzly cub in your den with momma bear..... Yes, I have issues!
I'm sure going the manual route is not for the majority, but I would have to guess that not everyone will want to upgrade and maintain an inherently problematic system either.... No matter- to each their own!
And last but not least- chances are getting new parts from Sunset or equivalent will be costly. Finding good used parts maybe an issue as well. At the end of the day, there is a very good chance that I will live with the PS. And I'll eventually get cut by the razor again!
P.S. Saw the strut bars yesterday- look real nice! Can't wait to get mine on!
P.S.S I have too much time on my hands....