Somebody please help

[CUDAchrisAUS]

I have been doing a Power to Manual steering conversion.
I have fitted the new manual steering box and got myself a Flaming River coupler.
Trouble is that when I install the uni joint there isn't any room for the DD shaft.
I have included a few pictures of the problem..
I know the DD shaft needs to be cut down but even if it was cut to its smallest lengh it wont fit
So first Q is does that look like the right manual steering box for a E body ??
second is do you need to mod the column (I didn't think you did)
and does anyone have pics of a FR coupler install.
I am stumped even using the little ajustment you have with the nuts under the dash there is now way I will fit it with out moding something

[CUDAchrisAUS]

I have made a few measurements and I think it might be a manual steering column.
Only thing is I just removed power steering from the car.
I must say the steering joint was a bit dodgy and sitting lose with no pin.
Do you think this is at all possible???

[HP2]

The steering box is correct for the application. What you needed was not a u-joint, but rather the column extension. See here for the power to manual conversion adapter.

http://chucker54.stores.yahoo.net/mamastad.html

[wally426ci]

i think you can find that on 70's B-vans as well if you're cheap like me. 

[CUDAchrisAUS]

The steering box is correct for the application. What you needed was not a u-joint, but rather the column extension. See here for the power to manual conversion adapter.

http://chucker54.stores.yahoo.net/mamastad.html

Thanks for the reply but what I'm using is a column extension that lets you get rid of the factory box to column joint.
My problem is I think maybe I dont need the extension 

[Chryco Psycho]

I think there was a member here going the other way , you could just swap the steering shafts with him !
 with the parts you have you wouls eem to have to trim the factory shaft down & use the shortest possible piece of the adapter shaft

[HP2]

Does the joint require the flats?

Well, if the OEM shaft is long enough, maybe you could mill the flats in to it to match the u-joint.

Other option is to cut back the OEM shaft some amount to allow a piece of the D shaft to connect.

Ultimate way would be to disassemble the column and have a new, custom shaft made to fit the OEM upper sections with the longer D shaft end.

If you rebuild your stock coupler, you can eliminate the majority of the slop in it and won't need to adapt a u-joint. Rebuild kits are only $25 or so.

[hemiken]

Hey Chris, looking at the pictures you posted, the steering knuckle is down too far on the steering box and has enough room to slide back up on the shaft, the steering knuckle will work on its own without the extension you have. Take your steering column out of the car, and if you are good with a grinder, you can duplicate the Double D shaft on the end of your column shaft, copy the end of the Double D end with a small piece of paper, cut it out and transfer the stencil you have made on to the end of the steering column shaft, when using the grinder, cut it out using a cutting wheel on the grinder and take it slow so you do not put much heat in to the end of the shaft, you should be able to work out how far up the shaft to cut away, i would cut the shape to the depth of the inside length of the Double D knuckle length in the top side of the knuckle.
If you have any questions you can shoot me a PM or call me, ask Adrian for my number

[brads70]

Hey Chris, looking at the pictures you posted, the steering knuckle is down too far on the steering box and has enough room to slide back up on the shaft, the steering knuckle will work on its own without the extension you have. Take your steering column out of the car, and if you are good with a grinder, you can duplicate the Double D shaft on the end of your column shaft, copy the end of the Double D end with a small piece of paper, cut it out and transfer the stencil you have made on to the end of the steering column shaft, when using the grinder, cut it out using a cutting wheel on the grinder and take it slow so you do not put much heat in to the end of the shaft, you should be able to work out how far up the shaft to cut away, i would cut the shape to the depth of the inside length of the Double D knuckle length in the top side of the knuckle.
If you have any questions you can shoot me a PM or call me, ask Adrian for my number

I'd add make sure you mill/grind the "D" in the right spot or the steering wheel will be off ( if it has a master spline?)

[CUDAchrisAUS]

All sorted..thanks to everyone for your help

[hemiken]

Look forward to the pictures of the fit and fix when you get the chance buddy

[CUDAchrisAUS]

Will some pics up soon