The spacer trick done with a specific sized washer was confusing until I saw how it works. It's actually quite simple.



Picture where the tie rod screws into the steering rack. The tie rod has about 2" of thread there. Well, unscrew it from the rack, add the washer which is about a half inch wide but small enough diameter to fit inside the rack. So now instead of the bump stop hitting the rack at the normal spot, the tie rod moves inside the rack a 1/2" more before the bump stop of the tie rod hits the rack.

 

Could I just machine down the bump stop? I took apart a spare rack I have and that looks like the best way to do it. Wouldn't that work the same as adding a spacer?

 

Wouldn't it be easier just to put a 4mm washer on there since you have it apart anyway. The only problem I see with grinding the bump stop is that you cannot reverse what you have done. With a Washer or aftermarket rie rods then you can always change it back out but once you grind something it is gone forever.