Guys heres my solution for less play in the steering box ! With some new FK rod ends as sugested by Bearfoot in another post the steering should feel much better.
I also intend to grub screw the steering boss to the shaft to eliminate play in the steering wheel, obviously I will lose the convience of a quick release wheel but I dont use it anyway.

The material used is .6mm Zinc, tried .4 to begin with but still had slop.

x2
the new fk's will make a big improvement on the steering...
keep us posted with any updates... good idea

Mick, How will you hold that in? Will the face plate and rack gear hold it?

There is a wear resistant tape available, that would help parts slide by each other.
Here's some info ...

Strong and Slippery UHMW Polyethylene Tape with Super-Bond Adhesive All the benefits of strong and slippery UHMW (ultra-high molecular weight) polyethylene tape on this page, plus a super-high bond adhesive make this tape perfect for difficult-to-bond surfaces such as powder-coated, plastic, foam, and metal surfaces. Adhesive is a high-strength, chemical-resistant acrylic. Temperature range is 0° to 200° F; apply at 70° to 100° F. Supplied on a cardboard spool. Color is translucent.
0.012" thick tape has a 0.01" thick film with 0.002" adhesive.
0.022" thick tape has a 0.02" thick film with 0.002" adhesive.

Here's another super slick tape. Kinda pricey, .5" x 180" = $19.95

Wear-Resistant Antifriction Rulon Tape Often referred to as bearing tape, this PTFE (polytetrafluoroethylene) tape has a self-lubricating surface, resulting in a low-friction tape with higher abrasion and wear resistance than regular PTFE tape. Great for applications requiring high temperature and chemical resistance. Ideal for use on bearing liners, chutes, and guide rail coverings.
Tape is 0.010" thick and consists of 0.008" thick film with 0.002" of silicone adhesive. Temperature range is -100° to +500° F. Tape is supplied on a cardboard spool. Color is dull red.

Find it at, http://www.mcmaster.com/#high-performance-tape/=8pqx58

Mick, wile you have the lid off, why not drill and add another grease zerk fitting?
They seem to wear between the lid and the rack gear.

This would be the place to put the antifriction tape too.

Bearfoot,
Your a wealth of knowledge mate, should call you Bearfootapedia !
When the lid screws down it is held in. I noticed that the spacer block in front of the rack gear is slightly smaller then the rack gear & when the rod end bolts are loosened you can move it up & down slightly, I moved it up as far as it would go then tightened the bolts, this left the top of the spacer flush with the top of the rack gear but at the bottom there is a discrepency of less then 1mm, hence the reason for the play. The metal I used is softer then the spacer so I expect it to wear 1st although it isnt as soft as the alloy so the lid will probably wear , I figure it wont be too difficult to machine the lid or fabricate a new 1 if or when it flogs out. I would have preffered to of made my new thingy to fit on the top side as I feel it would have meshed the gears closer together but had no way of holding it secure plus it wouldve worn the alloy underneath rather then the lid. I like your idea of the wear resistant tape but dont think i need it at this point, wouldve been perfect if installing the new thingy on the top rather then the bottom. Wish I had of thought to install new grease nipples prior to re-assembly, next time !
I'm yet to field test it but I have to say that sitting in the shed it feels a whole lot better. I will up date after our next ride.

Bearfootapedia, I like that!

I was changing the oil today and the gear lube. After reading your post, I thought I better lube up the steering box. The grease goes in red, comes out metallic silver! Ouch.

I looked at your photos again, and noticed that rack gear is rubbing the sides. Is that what you saw?
Just a thought.
How about making a 2mm shim, of UHMPE plastic, or teflon sheet, the same size and shape as the lid? Then use longer bolts, if needed.

Attached Images

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Revolt-Riot Box Shim.jpg (26.5 KB, 55 views)

Ive lost you with the "rubbing the sides" , where exactly do you mean mate ? I like your replacable spacer idea ! Can you make me 1 while you at it !

Grub Screws

I was thinking it was rubbing between the rack gear and the case sides. No?

Yes I can make you one. I ordered the material last night. I'll email ya when its done.

I like the wheel fix.