ididit Retrofit Steering Column: 1965 Mercury Comet - Manual (Page 5)

Starting from an 1/8 from the bottom, wrap the paper template around the
shaft and match the horizontal arrows together.
Mark the shaft at the 8 vertical arrow points and draw a line down the
length of the shaft, connecting the marks. This will create the shaded “D”
sections found on the template.
With a grinder or similar tool, grind flat the shaded “D” sections to match
the DD shaft. As you work, use the coupler as a guide and test fit to ensure
proper fitting.
Another option would be to
remove the gearbox and take it to your local
machine shop to be modified.
Once the shaft is modified, slip the DD
end of the coupler onto the gearbox
shaft and tighten the set screws. This
will tell you where to spot drill for the
coupler. We recommend using the point
of a 5/16” drill and drill into the shaft
approximately 3/16” deep. This will
allow you to anchor the set screw to the
shaft. (Figure 7)
Use Locktite and install the coupler’s set
screws and jam nuts onto the gearbox
shaft. The gearbox is now ready to go
back on the frame. (Figure 8)
Figure 7
Figure 8
3
Note: Diagram
not to scale
.395
.945
1.525
2.075
2.356
1.000”
DD SHAFT
TEMPLATE
To make 3/4 DD shaft
remove .100” from opposite
sides of the shaft
Original Shaft
New DD Shaft