Is there a secret I should know before I cut my DD column shaft?

 

Hmmm....measure twice!!

I made mock-ups out of wooden dowels, then cut the DD shaft to match the wooden parts.

 

Well I measured 9.5" from end to end. Then there's about 5/8" inside the u- joint so the set screw can touch DD shaft. So I figured 10 3/4" should be about right. Anything else I should know?

 

Yes...make a mark in the DD shaft where the set-screws hits it. Use a drill to dimple the DD shaft so that the set-screws goe into that dimple. Something around a 5/16 drill will do it....drill just so the angled tip of the drill is in...then stop.

 

I was told that make sure the shaft are too long and touching could make noise

 

Touching could make noise? Please specify

 

I dont know really i am guessing botteming out, you could get a viberation or something i just made sure i left a small space

 

Had this setup on my mustang. The last thing I'd do is make sure and use loctite on the set screws.

 

What lilrobo means is the shaft ends should not contact the center trunion in the U-joint. <cite>google borgeson u-joint instructions I can't link to a pdf</cite><cite class="_Zd"></cite>

 

I'm not finding crap on how to cut and install DD shaft.

 

Go to www.borgeson.com click on picture of catalog and tech guide to download pdf. There is a lot of suggestions on shaft and U joint installations in the catalog. Other than making it the right length (see above) and phasing the joints (same as a drive shaft) see page 6, page 25, page 27, page 29 of the catalog.
Cut the shaft with hacksaw, cutoff wheel in angle grinder or chop saw. Chamfer cut end with grinder to make insertion easier.
If this doesn't cover your questions you'll have to be more specific.

 

Thx ax. That helped a lot! Exactly what I needed

 

Well, I did it. Had to cut it 4 times because I didn't wanna cut it too short. It's very close to the header flange, I'll have to ask my exhaust guy what he wants to do. I don't wanna add a third u-joint.

 

It's hard to tell if it is too close or not from a picture, but I'd think 1/4" would be enough, otherwise you might need to get out the ball peen hammer and gain some more clearance. A third u joint would also require an intermediate support, but it would gain you plenty of room.
Double check the clearance while turning the wheels, the intermediate shaft may wobble slightly while turning.