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Cut the built up patches of the frame and fix it correctly so you don't have to re-engineer the steering. I can't count how many threads I've read about someone hacking a repair, only to have to change other systems to make it work right. You're going to have to shorten your drag link which will effect steering geometry, might end up with more bump steer.
Most street rods with custom steering I've ever looked at just dimple the shafts and use a knurled set screw on the joints, or they're drilled and cross bolted, very rarely are they welded. Once it's together, there's no chance of it pulling apart unless there's a major accident. Personally, I'd just weld it with my 110 mig. It's not structural, it's not under extreme forces and if you're putting so much heat into the shaft you're worried about weakening it you probably shouldn't be welding anyway.
Thanks for your concern. I don't consider my repair "hacking a repair job." It was a badly cracked frame that was repaired in a professional manner and is now being driven. It has never driven so well. The only thing shortening the column will do is return it to its oem position relative to the seat.
I've decided to take the shaft to a machine shop and have them cut it down and cut a new spline gear on the cut end.
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