Steering column alignment question.

[Bluemanx]

I'm replacing a cracked dash on an original '69 Manx. I've dealt with several VWs and after 45 years of wishing I am starting on refurbishing a Manx buggy. I am NOT doing a body off restoration, just redoing the necessary items to make this a nice ride. Overall it's in great shape and has been stored for 20+ years.

I know.... the hard top goes on the outside in back, just another example of the original build.
So far, I have taken the hard top, windshield, headlights, dash and hood off. The gas tank has been professionally cleaned and coated. New fuel line has been ran. ALL of the old wiring has been ripped out and I will build my own harness with what I've learned here on Samba (I visit every day).

I plan on replacing all of the brake components and replacing the steering box, as it is leaking, otherwise the front end seems to be good. There are US Indy Mags all around, 15x10 on the back and 15x8.5 on the front. I will try to make a trade in the future so I can put the 8.5s on the back and run 7s on the front. The current combination is just a little fat for me.
I'm currently replacing the ABS dash with one I received from Minnie and correcting the dash/windshield frame position.
So here's what I'm up against now and the QUESTION I've got for today:
If I line up the steering column during a mock up, things don't line up. Can I elongate vertically, the hole in the firewall/bulkhead so that the steering column is in the correct place on the dash. I have rotated the steering box to better align with the column per the original Manx installation instructions.

Location for steering column in new dash.

existing location of column thru bulkhead. I need to move it down about 1/2 inch to make things line up properly. Thanks for any help.
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If you don't have time to do it right the first time, ...when will you have the time to do it over ?

[Iguana]

Short answer is yes you can elongate the hole. I try to do it to the fire wall end not the dash end so you don't see it. BUT you must fit a cover plate when you do this so that the steering column outer has a support point.

Depending on what year column you have this may also effect your indicator setup.

The current Manx kits come with a three bolt bracket that covers the area and retains a custom grommet. Using a similar setup you get a bit more room for movement and when you are happy with it you can screw it in place.

Make sure you get correct alignment or it will rub and grind.

I would also avoid loosening your steering box and rotating it from stock as if you do it will give you more bump steer and create other issues.

This is the alignment you don't want

Here is the bracket, which should be bolted to the front wall and have the factory steering grommet fitted. What happens then is when it is bolted up tight the rubber gets squashed between it and the fiberglass and closes in tight.

Another common trend is to bolt a right angle bracket to the wall and then use a large hose clamp or muffler clamp around it and the column outer shell.

I hope that helps, if you need more pictures let me know I have a few buggies with bonnets off at the moment.

If you get stuck we also sell a Clam Plate which is in two pieces and you simply slide it together front top and bottom and bolt it to the wall. This way you can put it on when you are happy and not have to remember before you put your column in.

[BL3Manx]

[Bluemanx]

Thanks guys, I try to read and search before asking and the answer's usually out there, but I couldn't find this one and I was getting frustrated with the alignment. Iguana, that's some relief to know about the brackets, I'm pretty good at turning a wrench but don't weld. If you would, send me a PM with more info and maybe picts of the clam plate.
BL3Manx, I do like the idea of the u joints but like I said, I don't weld so I'm not very good on the fab end of things. Maybe I could have a buddy or shop do this for me. I have read about packing the box with grease but did not know it would apply to my situation, I'll try that before I spend 100+ bucks on a new box.
Bump Steer; what exactly is that? and I've read here it can be corrected with caster shims, no?
Yes I'll try to trade the 2 10" US Indy Mags on craig's list after I polish them up and see what happens, there should be a rodder out there just waiting for them.
Every thing on the pan is a '62 except the engine (74 dp) so the gearbox is swing axle, the Manx has most of the original options, front bumper, roll bar, skid plate and rear bar. I'm thinking of getting new 5x4.5 drilled drums for the back to tuck the tires in a little more but they don't seem available for the fronts. I don't want to go to the expense of disk up front and have heard here they're not needed. I've also read about putting front wheel cylinders on the rear to increase pressure where it's needed. The dash and wiring is next, so it will be a while, giving me time to learn and think about the brakes.
Winnie .... and Bruce .... I knew that Late and tired I guess.
_________________
If you don't have time to do it right the first time, ...when will you have the time to do it over ?

[andygere]

I second the request for info on the clamshell bulkhead fitting. Photos and where to buy would be great!

[Iguana]

[Iguana]

[andygere]

Thanks for the photo. Did you make or buy that bracket?

[jhoefer]

[wythac]

Another option for the hole in the firewall:

You can fiberglass the existing hole closed, then put the new hole where you want it. You can do it in such a way that you wouldn't notice the repair job.

Ill post more details if this is an option that appeals to you. I did this on both my dash and firewall steering column holes because I used a 3" lift. The existing holes were too high. The hole in the dash was just fiberglassed closed, the hole on the firewall was fiberglassed and a different hole cut (lower) because of the 3" lift. One of the easier repairs I did on the body.

[Bluemanx]

[Bluemanx]

[Iguana]

[Bluemanx]

So, ... I believe I'll go with double 7/8x7/8 smooth U-Joints for the steering shaft, sectioning the shaft, bolting in the U-joints and inserting another bearing in the tube. This should solve the alignment issue of the dash / bulkhead and keep the steering box at the proper angle, not to mention adding a measure of safety from what I've read here. Since this also involves the dash, I'm trying to address all the other stuff that goes with it, I've got some original switches and hope to use them. I want to keep this as "original" as possible, but I'm now thinking of putting in a '68 or later speedo, as the one I have either needs repair or replacing. I'd like to have a gas gauge (which I don't have) and I'm not crazy about using the mechanical one that is period correct for this '62 pan and cutting a square hole in my new dash. I'm now thinking I'll go with a speedo with gauge ('68+) and use the corresponding sending unit. Will this later sending unit bolt right in to a '62 gas tank?
_________________
If you don't have time to do it right the first time, ...when will you have the time to do it over ?

[RedBaronofRedBud]

[jhoefer]

[EVfun]

[L8ndeb]

I realise this is an old thread, but quick question for Iguana. Do you still sell the steering column clamps for the firewall? If so, please PM me as I would like to purchase a set.

TIA

[manxdavid]

[L8ndeb]

Yes David they do, but they appear to be out of stock.

Thanks anyway.