DONE! For those who responded to my thread and followed along, Thank You, appreciated. The fix that I ended up using was the Borgeson brass inserts that allow you to use the invert flare version of the return line. The kit comes with three inserts. First thing I did was to mike the hole diameter in the return port where the O-ring would have plugged in. Then I miked the inserts. All three come up at about 3/8ths which is the diameter of the tube. The port mikes out to about .010 or so wider in dia. All this means that the insert can be installed using finger pressure. Before you do that be sure to check the taper on the insert. The two that look alike, aren't. The difference in the angle of the taper is due to one being for invert flare bodied tubes and the other being for JIC style hydraulic ends. Both of these come with the same type of male nut and have the same thread pitch and diameter, it is just that the tube itself is flared differently in each case. The only additional step that I took was to deburr the lower face where the drill passed through. Not much of a burr but even a speck of brass could give the steering box a case of indigestion!.
Anyway. Tomorrow AM I have to phone NAPA and see if they have some more power steering fluid; the pump was dry and not sure how much was left in the box. Did elect to swap the belt that I had started with for one just a little shorter. Offers a bit more by way of adjustment and moves the pump slightly closer to the water pump leaving a little more room for the pulley to spin without "talking" to items around it.
Nick
Anyway. Tomorrow AM I have to phone NAPA and see if they have some more power steering fluid; the pump was dry and not sure how much was left in the box. Did elect to swap the belt that I had started with for one just a little shorter. Offers a bit more by way of adjustment and moves the pump slightly closer to the water pump leaving a little more room for the pulley to spin without "talking" to items around it.
Nick