I took it in for full wheel alignment on Wednesday only to be told the steering isn't as it should be and it catches
so I took it back to have a look at it after doing a few bits on the girlfriends Mini.
Only started on the Viva at 2ish and jacked the front up to take a look. I thought I'd cured the problem by chopping two of the bolts for the coupling down to stop them grinding on the column at certain turns, now two of the thick washers I'd kept from the old coupling were rubbing on the other side, so I had to undo the bolts holding the rack on to the crossmember and the rod ends to straighten the coupling and remove the two offending washers. Put it all back together and offered it up, and still wasn't happy with the acuteness of the angle, caused by all the other thick washers effectively making the column longer. So again I took it all apart, took all the thick washers out and stuck with just the smaller thin washers that came with the bolts, though these still spread the load over the metal sleeves perfectly. Put it all back together and it was much better except the bolts I originally cut down now stuck out much further again :
so they had to be cut down even further in situ and at last, I think I've cracked it! Steering felt much better and not notchy.
Took it back to be aligned and they were happy but it took a good couple of hours, so my girlfriend got the right hump as she wanted to go home. Stuck a load of tools in the boot just in case of anything (and so I could do some work when she wasn't looking) and made the 80 mile journey to Hertford in the rain, and it didn't miss a beat, so I'm happy.
Oil pressure was 50-60 running and nearing 20 at idle, so could be higher but I'll hopefully be able to get on with the other engine now, which will give me a few more ponies too. On the motorway I really wished I had a a lot more power and another gear or two, but that'll have to wait.
For now, it works!