shorten steering shaft

[Mustang1964s]

Well as most of you know my steering shaft broke on me last weekend.
The upper part just slipped out. The lower part was a challenge.
I was finally able to pull the lower part out.
I laid it down next to an old worn out steering shaft that I had.
As it turns out the shaft that I pulled out was about 4 inches shorter than a standard steering shaft.
When I get a good replacement, what would be the best method of shortening the shaft?
I have not yet found out if I can order one 4 inches smaller.
If I can't get a new one built shorter, then the only option left is to have a standard one taken to a machine shop and have the end milled down with threads and key way cut.

I really want to say away with welding the old shaft back.
If you can give me some good questions to ask the welder maybe he can put it back in one piece.
I have heard that if done right, it can be stronger than the original.

FYI This is not a standard steering column. It looks like the steering column has been shortened by 4 inches as well.

[Henry K. Lee]

You can always use a double D coupler. Install midway where the shaft comes though the firewall and where the steering box guide is. It requires milling on both pieces but would be a lot cheaper than having the end machined.

Hope this Helps,

Hank

[Sarikatime]

When I shortened a steering shaft for a special build, I cut the shaft between the firewall and the steering wheel where it will be hidden in the steering tube when finished. Be sure to sharpen both ends of the cut to be welded like a pencil so the welder can fill it in and grind it smooth afterwards. If you only butt cut and weld, you might have a broken shaft again and won’t fit in the tube and be an ugly sight when you lift the hood. Just thinking out loud. Frank

[Mustang1964s]

Would that coupler give the clearance of the timing and throttle rods?

[TRDxB2]

Couldn't see if you already answered this question: Why did the car have a shortened steering shaft? Do you need to do the same? Why?

[Allan]

There is an upside to shortening the shaft by re-machining the bottom end. That part of the shaft which runs in the lower bracket bush will not be worn, and that will make your steering assembly that much more precise.
Unless you need the entire shorter column assembly, it might be better to replace the lot with a standard column.

Allan from down under.

[Humblej]

You are playing with fire. You got burned because a prior owner had modified the steering shaft, and now you are contemplating doing it again yourself. The correct repair would be to replace the entire steering column with a stock Ford set up. Complete restorable steering columns are plentiful and affordable.

[John Warren]

If you need a short steering shaft, then cut the end off of a full length shaft and re machine correctly. Safest way period. For an experienced machinist, piece of cake. When my father was bigger, he could have used a shorter steering shaft.

[Henry K. Lee]

Yes you have clearance. I have double D couplers if you wish to go this way. It is the same method as modern vehicles with a collapsable column shaft, perfectly safe. You do not weld them, you pin them.

Hank

[TonyB]

The 1909 cars used a shorter column. I suspect some portly owners had the column shortened to provide a more comfortable driving position.
When I restored the 09 it had a standard 1914 column which is too long. After some consideration I decided to shorte both the shaft and the outer column and replace the quadrant. Machining the taper and the keyway was time consuming but not difficult. I would recommend NOT welding whether visible or invisible.
The most fun is installing the long rivets to hold the quadrant. Incidentally all this effort is described in the sept/Oct 2020 The Vintage Ford in my article “The Gift”

[TRDxB2]

..... FYI This is not a standard steering column. It looks like the steering column has been shortened by 4 inches as well.

You said in the very beginning that the steering column was shortened too. While there have been many suggestions on how to repair what you have only a few question why your interested in fixing a bastardized steering column & shaft. Replacing the steering column & shaft is likely to be less expensive and time consuming than salvaging someone else's improper fix.
What year/model is this T anyway, you never said or why you still want a shortened steering column.