A long overdue update.
I've done pretty much half my annual mileage in the car already!!! And the exhaust is doing my head in, Its not leaving the garage again till this is done! I'll be fitting a 1/4 wavelength resonator pipe to each side, with a sliding joint so it can be tuned to the right frequency then depending on the how that is I'm still thinking about pursuing the intercom route.
The other thing is bump steer, hands up who saw that coming after my new wishbones and uprights

Well I knew there was an issue from the start, you simply can't make a ball joint conversion without there being one. In a ball joint the steering axis and the axis through the end of the wishbone coincide and they do not in the trunion so I knew I would have to lengthen the track rods to take this into account. I've done all the calcs for this and found they need to be about 6mm longer each side. This is easily done with the steering arms being bolted to the uprights with great big spacers, simply turn the spacers down a bit

But what I hadn't though about was that I've make the upright about 45mm taller!!!!! The end of wishbone axis sits 45mm lower than in the original set up, compared to the top ball joint! This makes the 6mm track rod problem look like nothing. You can see this extra height in the following photos.



So after much calculating and trig and so on..... (and the race and rally source book, which is excellent for this sort of thing)

My options are......
*Raise the rack by 16mm and move it back by 3mm and extend the track arms by 6mm
*Lower the track rod ends by 20mm and extend the track arms by 6mm
*shorten the uprights by as close to 45mm as possible and extend the track arms by 6mm
My thinking is, instead of getting further into trouble, I'll take the option that gets the suspension close to the original and choose option 3.
More to come..