so over the labor day weekend, I went to pick-a-part and picked-a steering column & motor from a Saturn Vue. I actaully got 2, one from a 2003 and one from a 2004. I noticed the intermediate shaft is different, like slow-poke pictured. The 2004 intermediate shaft is thinner on top.
Anyway... Here is my plan.
I am starting with a early 67 coupe, so I have the long shaft attached to the steering box. The engine is out, so that will help.
On the lower 1/2 of the steering shaft, I plan on cutting the steering shaft in the engine compartment. About a foot up from the steering box. I will probably start closer to the firewall. I will file it down to a 3/4 DD and use the saturn lower intermediate shaft to connect to it. The intermediate shaft slides so I dont have to worry about being precise on the actual distance. I will eventaully put some set screws in the intermediate shaft to lock it in place. The only issue with this is if the Saturn shaft it too long, even shrunk down. If so, then I will look at a coupler.
On the upper 1/2 of the steering shaft, I plan on doing the same thing that FordForever did on The Falcon Forum Network. Remove the upper 1/2 of the collapsible column and remove the shaft. Cut the upper shaft and drill part of it out to 3/4 to fit over the mustang steering shaft. So one end of it will fit on the saturn shaft with splines and the other end will fit the mustang steering shaft. Some set screws to hold it all together.
So that will take care of the steering shaft portion.
Cut the column tube to length as needed. Cut and Bend some tabs to bolt it to the saturn motor casing. I may also get the firewall mounting plate that clamps to the tube.
the only grey area is fabrication a bracket to attach to the motor or to the pivot sleeve to support the motor and to keep it from moving.
I actually want to leave the intermediate shaft so that it can float up and down, but the Falcon Forum had some issues with the motor wanting to move up and down, so I expect to have to secure the intermediate shaft. However, I would think that if it is attached securely at the steering box and at the saturn motor, it would not move, so the intermediate shaft would not need set screws. Something to look at when I get to that point.
Comments welcome