33 Coupe Steering Column 4        11/2/03

I used 1/2" electrical conduit to mock-up the steering shaft. Now 1/2" steel conduit is really 7/8" in diameter so this is very close to the 1" DD shaft that will be used later.
 

 

 

I had to run the steering shaft near the engine instead of next to the frame rails like it was designed to do. Notice the extreme angle at the rack and pinion to see what I mean. I know it's hard to see but the rack and pinion is pointing toward the frame and not the engine.
 

 

 

This is a shot of how close the shaft is to the header flange. I can gain some much needed room by shortening the splined area of the shaft above the U-joint. So I'll be cutting this splined area by 1/4" with a hacksaw. Now this is over 1" in diameter but is hollow so shouldn't be a big deal.
 

 

I had already spot-drilled the column for the setscrew that is on the U-joint before I decided to shorten it so another spot-drill will have to be drilled after cutting.
 

 

 

Here is the piece that was cut off and now all the splines have to be deburred. I used this triangle needle file to work all of the splines so the U-joint would slip back on. The cut and deburr took 45 minutes to complete.
 

 

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