List,

The critical thing with a rack and pinion conversion is not the overall
width of the rack. You need to measure the rack between the joints that
the tie rods hang off. This distance must be the same as (or VERY close
to), the width of a standard 1600 drag link.

This will maintain the same relationship of the distance between of
lower control arm pivot points and drag link length of a stock 1600.
Which in turn gives the same ratio between lower control arm length and
tie rod length, (measured from ball joint center to center for both of
course). 

Imagine looking at the tierod and lower control arm in a plan view, when
you turn the steering, the two move as a parallelogram. Changing length
of one might not seem like a big deal, but if you now imagine looking
from the front with one longer than the other, they will be at different
angles to start with, turn the wheel and move the suspension up and
down, the rod and arm will move out of plane with each other even
further. This is what produces bumpsteer, which could literally drive
your car off the road for you!! 

As for racks to use, I think I have heard of the BMW conversion too. I
think the rack to use would need to be out of the earlier E21 3 series
(pre 1983) as I'm pretty sure this rack is mounted rearwards. The E30 3
series (1983-4 to 1991) has it's rack mounted forwards, so would be no
good.

To forward mount a rack you need to move the tension rods from front to
rear, which I think would mess with the suspension geometry even more.
And well tension rods are called tension rods for a reason.

One idea I have been think of is a complete swap to BMW E30 suspension,
(both front and rear to maintain track relationships). The rear is same
sort of trailing arm setup that the datto uses. But the front has much
better castor and allows you to use the front mounted rack and pinion
steering. The E30 BM was renowned for its fantastic steering response.
(I know because I owned one about 4 years ago). Both cars have fairly
similar overall dimensions.

Only problem would be getting the parts for the right prices.....

Hope I haven't bored anyone too much, and I still own a BM so don't tell
me to go buy another, haha. I love my Datto just as much.

Regards,

Andrew S.

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