super stiff steering

Are you sure you get the right box in 24:1?
Count the steering wheel turns from stop to stop. A 24 is really easy to turn. Disconnect the rod ends at the pitman arm, it should turn smooth and with no endplay in the middle, so you are sure your box and column is ok.

Yeah that's next on the agenda. I won't be able to work on it until the weekend but once I get the chance I'll find the lock-to-lock turns and find the ratio. I also want to disconnect the idler and see if it binds.