Steering gearbox Welch plug

[James7]

So I bought a used steering gear from SS, they sawed off the column and input shaft so I am trying to take 2 boxes and make one. So original box had no Welch plug hole machined in it and the used one does but plug is gone. Looking to find a plug without buying 5 or 10, nothing local found. About 1 1/16?

 

[James7]

 

[James7]

My first time posting images, hope it works out. I could even just make a disc to plug the hole and stake it in and seal it if I don't find a plug.

 

[DanR]

James, If your first PIC is showing a "hole" the Welch hole as you call it is where the inner bearing race is supposed to be secured for the worm gear to "ride".

Just any ole plug is niot going to work. Most likely the steering box is not going to be serviceable unless you re-install a bearing race.

Is the steering box in the 2nd PIC serviceable?

 

[James7]

Thanks for the reply, the box in the bottom picture has a cracked housing so I bought a used box from sunbeam specialties. It’s in pretty good shape inside and the lower bearing race is in there but the “washer “ as the service manual calls it is gone. No cracks are seen around the hole. I have contacted SS numerous times about getting another box from them or at least a good input shaft since they sawed it off to ship it! No response though. My old one is rough where the balls ride in the worm groove but I was going to reuse it and see how it works out.

 

[DanR]

Before you use the old one...... What is the length for the sawed off one ?

I may have a solution.

 

[James7]

Ok do you mean the length of what is left of the cut one? This has the adjustable column on this car by the way. The cutoff one is in the picture there, the end is barely visible. Probably a little over a foot long. Noticed the shafts are hollow, I suppose if a guy really wanted to be creative you could cut them and pin it together and weld it but this is actually for a friend’s car so not looking for liability issues if it ever failed.

 

[DanR]

what is left of the cut one?

Yes!

 

[DanR]

And YES, the shafts are hollow.

I have made some "pins" that are the same OD as the ID of the hollow shaft. Which can be utilized to lengthen your "short shaft". Just make sure your joint is true before and after welding them together.

 

[James7]

Thanks Dan, I wondered if anyone else had done that. I assume keeping the length the same is pretty critical but what about indexing the worm gear to the original shaft? Can’t remember if there is a master spline at the steering wheel or not or would that even matter? Thanks for the advice.

 

[Bill Blue]

Overall length is important, not necessarily "critical." Indexing, totally not an issue. The shaft has fine splines, not coarse ones that more than likely would be sensitive to indexing. Keep it straight and close to length and you'll be fine.
Bill

 

[James7]

Thanks guys, good to hear from someone that’s been there done that. Can’t just run to the parts store and get this stuff. This original box from the car was really a mess inside.

 

[DanR]

Indexing, totally not an issue

Indexing is not an issue except for the upper outter column for the alignment of the two (2) piece Cowling. The upper outter column has a little oblong raise the is weldedd on to guide the cowling. Take a careful look and you will see what I am referring too.

 

[Toyanvil]

What series is your car? I may have a good input shaft from a late series. It took me three steering boxes to get all the good parts I needed to rebuild one for my series 2, the later series input shaft is not the same so this is leftover. This is a link to my rebuild that may help you. Steering box rebuild

 

[James7]

Series V, 1967 with adjustable column. I am pretty sure I saw your rebuild posted somewhere before, amazing! Looks like a $10,000 gearbox!! And what were you heating the housing up for when hanging outside?

 

[Toyanvil]

Here are some pictures of the one I have and a link to more. It looks to be in great shape. Sunbeam steering shaft

 

[James7]

Looks really good, either I weld up my shaft the way DanR advised or just buy yours, that’s less work so you can give me a price, thanks

 

[Toyanvil]

I will PM you.

 

[Bill Blue]

Looks like new. I don't think I have seen a steering shaft outer end without any raceway galling until this one.