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[chrisgixer]

Packaging... isn't that management speak for compromised design

Yes indeed. But I sympathise in this case. A straight rack isn't possible. As defined by the u shape of the centre tie bar.

[05omegav6]

I take it the tweo 'teeth' are spaced to match the ends of the tie bar

[Gaffers]

Surely this is where you ask the master very very nicely

[chrisgixer]

I take it the tweo 'teeth' are spaced to match the ends of the tie bar

Nearly. Teeth are spaced to match the centre lines of the wishbone pivot points. Which is tricky, as they are not parallel, son it depends where the travel bar sits for and aft. Like I said, mk1, hence the rather rough appearance. But gota start somewhere.

There will have to be a guide, to prevent twisting, which will depend on ride height>bump>wishbone and hence track rod angle pushing the travel bar up and down. This will bind the rack on the pinion gear.
 It's also evident when turning the pinion shaft, due to the pinion angle, the rack twists slightly. Not normally an issue as the track rods are normally on the end of the rack. So the position if the inner ball joint won't move. But with the travel bar, a slight twist, and it's only slight, then the inner tre position moves up when turning left, and down when turning right.

[chrisgixer]

Surely this is where you ask the master very very nicely

Why should he get all the fun?

This isn't a project of any urgency. As you may of noticed it's a learning process as much as anything.