Steering box now finished. I had originally chosen the best sector shaft & best worm gear shaft, but despite several attempts, I could NOT get them to work together without binding mildly in what would be roughly straight steering. Had a re-think and tried the other worm gear shaft. Bingo! Smooth rotation from lock to lock. When adjust fully, it is now possible to turn the worm gear shaft by twisting the sector chaft alone. These two parts had been a pair for 70 years and they still work perfectly together.
Assembled the box fully yesterday PM, after returning home from photographing those old CMP wrecks. Checked the assembly this morning and found some oil weepage from both of the bolt on plates. Very minor, but shouldn't be any leaking there at all, they both have brand new gaskets. Re-torqued the bolts this evening, for another check in the morning. I would hate to think I need to remove the cover plates for some reason
Heres a small glimpse into the distant future.
The new sector seal was installed easily but painfully. With weather being so hot, I put the bare steering box in the sun, and the seal had gone into the freezer the night before. Upon removal from the fridge, the oil that seal was sitting in had turned thick, as thick as treacle! When I took hold of the steering box after sitting in direct sunlight for 4 hours, it was VERY hot. I unwittingly reenacted the scene from Indiana Jones where the bad guy grabs the medallion thats been in the fire.
The difference being, the writing wasn't as clear on my palm......and i'm not a fascist nazi bully boy.
With the differences in temp, the seal could be tapped in easily. At least that bit doesn't weep oil.