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Reply to "Hey Lane"

double u-joint

@Gordon Nichols,  I have one of the clamps you suggest but I can't see how it would help here.  At the rack end, you can see the set screw with a nylock lock nut.

I thought about drilling straight through as you suggest but thought maybe the rack shaft would be hard to drill.  Also, I would be making the rack shaft weaker.  The cross-section is already reduced by the flat side.

At the steering column shaft end, the set screw goes into a groove in the splined bit.  So, it just keeps the shaft from going in and out of the tube.

I have a super beetle steering shaft with a u-joint on each end.  I might be able to shorten it.

Or, maybe I could just trust that the set screw won't shear.

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