Step number 36in the instructions says this:  

Working on the stock driver side rear lower control arm pocket, carefully cut the stock driver side rear lower control arm pocket to allow for proper clearance for the stock rack and pinion high pressure lines.   Please see photo # 3 for the proper cut lines.   Special Note:  Tuff Country deos not recommend using a torch when making this cut.   Take special care not to cut any lines, hoses or wires.   This is not an easy step, please take your time and do not cut out more material than is necessary.   If you have any questions, please do not hesitate to call the technical department @ Tuff Country.
Photo # 3

This is a VERY difficult step as I have come to know!   When I first did the cut, it did not seem too bad.   However, when I went to put the rack in place I found that I had not cut enough marterial.   Cutting more off later is not so easy!    Below are additional pictures and info.   Hopefully they will save some others from having to cut more like I did!

 

Here you can see what was left after we did the first cut.   You can click on the picture for a larger one...
Here is a close up showing the low pressure return line almost touching the metal on the edge of the cut.
In this picture you can see that we have cut some additional material to help clear the low pressure line, but the nut on the high pressure line is against metal also.
Here is a close up showing the high pressure nut against the metal.   (see arrow)
This is a picture from rear of the lower control arm pocket.

Here you can see that we have cut some more metal off, but the high pressure line is still hitting!

You can click the picture for a larger image.

At the end of the day, and a few hours of playing with it, this is all the additional metal we removed after the additional cut.   You can see that it does not take much to make the difference.
4-1-2004
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