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I think this has to do with the small amount the drag link sensor moves in and out which will add a little play in the steering. Like you, I noticed a little looser feel on a stock truck.

Not too bad. It doesn't do much at a standstill but is a very big improvement while moving slowly. I'm running full truck pressure (no regulator) and the performance drops way off under 90psi. I have noticed a little hesitation in the assist picking up at the very beginning of steering wheel...

Eastern Surplus appears to be using some type of poly bushing to support the shaft inside the cut tube. This may work but I'm wondering if a bearing would be better suited for this. Any wear in this area is going to result in slack in steering.

The way I understand it, the torsion bar only controls the valving. The shaft goes straight through so even if the torsion bar broke you would still have manual control. I'm seriously considering this setup (Woodward servo). I may need to start a new thread but I'd like to talk about some...

I don't think there would be any timing involved in a servo system. The one I listed in the link is also fully adjustable. You would need to size your cylinder correctly though.

I'm not necessarily disagreeing with you but I am curious as to why you think the Ross box is a better route? I'm leaning toward the servo at the moment but I still could be persuaded otherwise.

Here is a servo valve I came up with- http://woodwardsteering.com/images/power%20steering%20system%20components.pdf Looks like this may be a good option. It's cheaper than the torque generators I've found and it will not put any more stress on the stock steering box (it will actually lessen...

That makes sense to me. I knew about some of the problems you mentioned (fixed displacement of orbital valves and difference in displacement on each side of cylinder) but haven't really thought it through. I was worried about this anyway and you confirm my suspicions.

The way the torque generator works is it uses hyd pressure to assist on the output, it's all self contained (no cylinder the drag link or tie rod). During normal driving, it's unlikely that the torque generator would put any more stress on the stock steering gear (it takes "X" amount of torque...

Since I made my post in this thread yesterday and read the comments, I'm going to hold off on the torque generator and explore using a orbital valve from a hydrostatic unit. I've got several hydrostatic units in my stash of parts that came off various scrap equipment so it won't cost me anything...

I think I'm fixing to bite the bullet on one of these units. Anybody used one? I'm thinking I could just put this in line on the steering shaft and not have to even add any u-joints.

92ft/lbs would make a heck of a difference. I'd bet the air assist doesn't put out near that much at 120psi and the cylinder is mounted were you don't have the advantage of the stock steering gear reduction as you would with the torque generator. What's the stock gearbox ratio? That would tell...