I've been researching this for a while and cant seem to come up with a straight answer. Im using my stock steering column and steering shaft but a mustang 2 suspension. I need to attach a u joint to the steering shaft. What is the best way to do this. I was planning on carefully grinding two flats to make it into a double d at the end, but the fact that the shaft is hollow has me worried that it might make it too thin. I dont feel comfortable using just a single small bolt and i've read that welding the u joint is not a good idea. What have others done that have used the stock steering shaft?

 

I have seen where someone threaded a bolt into the hollow shaft. I don't think there would be a structural issue with grinding to a DD (the hole isn't that large) if you drilled it for a thru bolt rather than a setscrew to secure the U joint.

 

I think turning a steel plug to insert into the stock shaft, with some provision to attach to the u-joint, would be the safest. Plug weld the plug to the shaft and weld all around.

 

Exactly how I would do it. If a section of 3/4" DD could be turned down on one end to fit inside the hole it would work perfect, otherwise a piece of solid tubing turned down one one end and machined to 3/4" DD on the other.
Turned down end of the adapter pushed up into the original column 1" and a steel pin put thorugh both pieces and welded on both ends.
I may be doing this as well since I am not totally happy with the column I mocked up in truck #2, original looking could be cool.

 

I just received one of these. 3/4: straight on one end and 3/4". I will drill and pin the straight end to the column.

http://www.summitracing.com/parts/brg-114964/overview/

 

Thanks for the ideas guys. I think im gonna try what Ax sugested and fill the hole with a bolt or slug and grind a double d into the shaft. I might be able to talk to some of my old teachers from high school and see if i can use the vertical mill maybe.

 

The shaft is just mild steel and can be ground/filed fairly easily. Don't leave the end of the ground area with a sharp corner, but blend it from the flat to round.

 

I took my steering shaft to a welding shop and had the u-joint welded on the shaft then drilled thru the setscrew hole and ran a grade 5 thru the hole. Nice and tight with no problems yet.

Ken

 

Steering Shaft, 3/4 Inch O.D. Double D, 4-16 Inch Lengths, Steel - Speedway Motors, America's Oldest Speed Shop

I would purchase one of these in the size I need. Turn one end down to the ID size of the existing steering column and slide about 3" into the column shaft and than tig weld. If I did not feel comfortable with welding this I would take it to a certified welder.

My next choice would be the way flattie39 did it

 

Here's someone facing a similar issue, with a solution:
Modifying a ford F1 48-52 Steering Box to accept a late model steering column - The Ford Barn

 

Now im leaning more towards what Ross suggested. Im gonna try and figure out how how much material would be left if i ground two flats into the stock shaft though.

 

I don't care for my column either...Bronco II plastic crap...I will probably just buy a simple straight column, but I would love to keep it tilt, yet have the original style external mount turn signal switch.. $300+ for tilt isn't in my budget, and I still want that original look in the cab.

 

What will you do for a horn, Nick?

 

I honestly haven't given it much thought yet. I know mid fifty sells a kit that lets you use the stock horn button with the modified steering shaft, but im not sure if i wanna spend that much money just to keep the functional horn button. Ill have to do some more research and see what other people have done.

 

I would think about getting a chunk of double D shaft, making a bullet to fit inside of the stock shaft, drill a hole in the double D piece, insert the bullet then drill and pin both sides and then weld it all together. On mine I had another person make a new solid steering shaft for me with a double D end.