Outer Limits 4x4 Board

looks like im going to have to shorten my steering shaft.....
looking for some opinions and sugestions on best way to do it...

situation is:
92 hilux being fitted with GQ diffs and coils
using original panhard mount(front) that has the bolt holes for the steering box through it(makes positioning easy )
BUT the stock steering shaft is touching the end of the shaft on the box(GQ) so no room for rag joint so i need to shorten the shaft.

is cutting and shutting and sleeving a good way to go?
anyone got a better idea?
Any help would be appreciated.......
i have access to a lathe so i could turn down a new shaft that slots inside old one and slide it up inside and weld through holes drilled in original shaft?

Is the shaft solid?

Is this car registered?

Welding is not the answer in an engineers mind for any steering components. Otherwise you would have to get it xrayed/tested.

Just as an example. Sierra's made in the 90's Had a telescopic/collapsable type one. So in a heavy hits, the shaft will snap little plastics locating pins, and slide into itself.

Many "suzuki drivers" have done a vit p/steer conversion and needed to shorten their shaft. So they drill out the pins, and slide it into itself.

Any later model lux's have this?

I lengthened mine, sleeved it welded the ends and plug welded it, been like that for about 5 years. You could do the same to shorten it. DOT would probably have something to say about it though.

BlueSuzy wrote:Is the shaft solid?

Is this car registered?

Welding is not the answer in an engineers mind for any steering components. Otherwise you would have to get it xrayed/tested.

Just as an example. Sierra's made in the 90's Had a telescopic/collapsable type one. So in a heavy hits, the shaft will snap little plastics locating pins, and slide into itself.

Many "suzuki drivers" have done a vit p/steer conversion and needed to shorten their shaft. So they drill out the pins, and slide it into itself.

Any later model lux's have this?

the collapsable/telescopic part of the shaft is to stop you being impaled by the steering shaft on a frontal impact. Shortening thhe shaft like this is probably no the best idea. I would be more inclined to cut,sleeve and plug weld as sloshy has done. There would be far less stress on the steering shaft then on other steering components.

I have a Toyota shaft here for a PS conversion.. Its welded. I have a hilux shaft here, its welded to the rag joint. I have a 60 column, its got welded shafts inside it..
Obviously the shafts are robot welded and machined, but do you think each and every one of them are inspected?
These shafts have been around for years and caused no problems..

Have it shortened and resplined..

vk7ybi wrote:I have a Toyota shaft here for a PS conversion.. Its welded. I have a hilux shaft here, its welded to the rag joint. I have a 60 column, its got welded shafts inside it..
Obviously the shafts are robot welded and machined, but do you think each and every one of them are inspected?
These shafts have been around for years and caused no problems..

Have it shortened and resplined..

they are production items and the originals would have been tested and certified,

not anyone is capable of quality welds this is why engineers would want them tested,

80's_delirious wrote:

BlueSuzy wrote:Is the shaft solid?

Is this car registered?

Welding is not the answer in an engineers mind for any steering components. Otherwise you would have to get it xrayed/tested.

Just as an example. Sierra's made in the 90's Had a telescopic/collapsable type one. So in a heavy hits, the shaft will snap little plastics locating pins, and slide into itself.

Many "suzuki drivers" have done a vit p/steer conversion and needed to shorten their shaft. So they drill out the pins, and slide it into itself.

Any later model lux's have this?

the collapsable/telescopic part of the shaft is to stop you being impaled by the steering shaft on a frontal impact. Shortening thhe shaft like this is probably no the best idea. I would be more inclined to cut,sleeve and plug weld as sloshy has done. There would be far less stress on the steering shaft then on other steering components.

If the shaft is solid. They may have a different crush system. Suzukis are very basic, so this sleeve telescopic shaft is the main safety item. I didnt shrink it much, only 10mm.

Alot of cars have a cage/mesh like mounting around the actual steering column inside the car. These crush in heavy impacts. Maybe hilux's have this type?

BTW, my 88 suz lwb has a solid shaft. so if i hit the front with anything, the wheel is heading directly for my face...

BlueSuzy wrote:

80's_delirious wrote:

BlueSuzy wrote:Is the shaft solid?

Is this car registered?

Welding is not the answer in an engineers mind for any steering components. Otherwise you would have to get it xrayed/tested.

Just as an example. Sierra's made in the 90's Had a telescopic/collapsable type one. So in a heavy hits, the shaft will snap little plastics locating pins, and slide into itself.

Many "suzuki drivers" have done a vit p/steer conversion and needed to shorten their shaft. So they drill out the pins, and slide it into itself.

Any later model lux's have this?

the collapsable/telescopic part of the shaft is to stop you being impaled by the steering shaft on a frontal impact. Shortening thhe shaft like this is probably no the best idea. I would be more inclined to cut,sleeve and plug weld as sloshy has done. There would be far less stress on the steering shaft then on other steering components.

If the shaft is solid. They may have a different crush system. Suzukis are very basic, so this sleeve telescopic shaft is the main safety item. I didnt shrink it much, only 10mm.

Alot of cars have a cage/mesh like mounting around the actual steering column inside the car. These crush in heavy impacts. Maybe hilux's have this type?

BTW, my 88 suz lwb has a solid shaft. so if i hit the front with anything, the wheel is heading directly for my face...

from steering columns I have played with, the outer column has the mesh cage designed so the outer casing can collapse, the shafts have also been two part, joined with little plastic pins as described.
I have seen this in early 1970's holdens. Suzuki are a bit behind the times

I might have a look tomorrow with the sierra's compared to the jimny's. I'm unsure if they have the crush cage also...

The sierras telscopic has about 250mm of movement.

the cheapest and most legal way to do it is cut how much shorter you need off the splined end then get the thing re-splined from memory about $25 last one i got done