Custom Steering shaft

[TexasBronco]

This isn't 100% Bronco related but I think it can be applied to Broncos. My brother wants to take the top part of one steering shaft, and attach it to the bottom of another. The shafts are 1 1/2 inch in diameter and are hollow. First off... Can this be done? How hard will it be? and what steps would I need to take to get it done properly? I am thinking the ends of the pipes would need to be ground at angles so a complete pentration weld can be done. And making sure they were 100% straight when done as going to be hard. TIA!!

 

[Madgyver]

It can be done. The question is how well will it hold up? It all depend on the weld.
I thought of doing this with a later model tilt column so that I could use the stock rag joint, But I came across a 78-79 model tilt column.

 

[2badrotties]

The best way would be to sleave it. Either find a piece of tubing that will fit inside of the two pieces or a piece of tubing that will fit onto the outside. Inside would be best. If you do it this way the two pieces will be straight and strong. Drill a couple of holes through the outside piece so you can plug weld it to the inside sleave. Do you understand what I'm saying ?

 

[TexasBronco]

Yeah I follow you 2badrotties

 

[2badrotties]

I'm glad you understand. I can do a lot of things but it sure is hard to tell someone else how to do it.

 

[Past_Miner]

I did this with a tilt column from a '69 T-bird, but I had solid shafts to deal with. I would definately use a sleeve. Grind the tube ends at about a 60 degree included angle and leave about 1/16" square ends. I mean don't grind the tubes down so much that you have sharp edges to weld, you need a little metal there to keep from burning through. Leave yourself a small root gap and weld carefully.

To keep the assembly straight you can clamp the two tubes in a piece of heavy angle iron. Tack the tube in a couple of spots, let it cool a little and roll the tube over, reclamp and tack some more. You can then finish weld the joint while it is clamped in the angle.

 

[howiebilt]

I "bilt" my own using EB bottom end and 89' Crown Vic top . It has been working great for several years now . There is nothing that says you can't do anything you want and after reading several of your posts and responses , I think you know your own limitations and I also think you know when to ask questions . I think you should take some pics and post a write up for those who might want to consider doing this . The folks that don't have the knowledge or capabilities could at least take your "blueprint" to some place that could do the work for them

Good luck and lets see how it turns out