How to keep something straight for welding

[AlexGTR]

I am currently fitting a corsa c electric power steering column to my twin turbo V8 rx7.

I need to weld the steering wheel end from my Mazda shaft to a part that slides into the corsa column splined shaft.

I had a rod turned by my mates dad to put inside them both which I was hoping would keep it straight for welding but it has a slight wobble. I've tac'd it a couple of times but just can't get it straight and really don't want a wobble when turning the steering wheel!!

What is the best way of keeping it straight? Also what's the best way of grinding each end completely flat?

 

[Master fettler]

G Clamp the 2 pieces in a length of angle iron you know is straight and weld 1 side remove and weld the other side. How we used to do prop shafts in the past. Hope this helps you!

 

[Turbo]

I would suggest that you get a new rod machined that is a tight press fit in the tubes with a ridge halfway to act as a stop. You should supply the tubes to the machinest so that he can size them exactly.
Then as he said, use angle iron to keep it straight. But whatever you do make sure the weld is invisible when you are finished. The MOT man doesn't like welded repairs to steering & suspension components!

 

[AlexGTR]

Thanks for the suggestions guys will give them a try.

It won't be visible, it should hopefully look stock unless you put your head in the footwell and look up and unless you have one of these cars which is not common you wouldn't know the difference. The welds will not be having much torque applied as it's the steering wheel end, the torque from the motor is at the other end which goes to the rack and I don't need to do anything there.

 

[Ton-up]

When I did this a few years ago, I also put a rod up the inside but I machined half of the end away about 10mm deep on each shaft so when put together, they lock. I didnt fancy just relying on a radial weld.

 

[AlexGTR]

When I did this a few years ago, I also put a rod up the inside but I machined half of the end away about 10mm deep on each shaft so when put together, they lock. I didnt fancy just relying on a radial weld.

Not sure what you mean and how you got them to lock. Do you have any pics?

 

[Ton-up]

Lock might be the wrong word exactly, but a staggered joint like this......