A call to all backyard engineers (steering woes)

[sambo]

I've fitted a 90s model Ford Laser column to the cobra as per the Harrison specs. This will be mated to the VK Commodore power rack that is also now in the car. All the mounting brackets and pre-cut holes in the firewall look spot on... so far so good.

Here's a photo of the end of the steering column. It's a 36 spline shaft with a very odd diameter of 15.75mm as measured with digital vernier calipers.



I have both 9/16" and 3/4" 36 spline universals and they are too small or too big respectively. Doing the maths using 1" = 25.4mm, they equate to diameters of 14.285mm and 19.05mm.

Next is the line-up of potential suspects that I am trying to pin this engineering crime upon! Left to right we have the steering column, the factory Laser universal, the 9/16" uni and the 3/4" uni.



Before I go any further, this is nobody's fault but mine. Ordered the shiny bits without measuring twice - lesson learnt.

The rack has a 3/4" 36 spline shaft, and I have a length of 3/4" stainless to run up to the column shaft with uni-joints in between.

Is it be possible to safely mill the steering shaft down to 9/16" diameter and use the 9/16" uni? (which is 3/4" on the other side in keeping with the connecting shaft and rack).

Or would it be better to use the factory uni and mill the 3/4" connecting shaft down to that diameter at one end? Personally I prefer the idea of new parts over old, but I know they're not a high wear component.

Any other suggestions are welcome. Jokes and ridicule a close second.

Thanks,
Paul