Steering Shafts

The MK2 Scirocco uses a different steering driveshaft than other vehicles, see picture at the bottom. When swapping to a manual rack from a power rack, you need a steering shaft 20mm longer than the power shaft, and no such shaft exists except on a MK1 Scirocco with a manual rack.

In an attempt to replicate this shaft since it is hard to find MK1's, I've found some components that should work. The splines on either end re 11/16, 40 spline.

Borgeson Universal Steering U-Joints 014928

This u-joint has a 11/16-40 on one end, and a 3/4 DD shaft on the other end. Two of those, with a length of shaft custom cut to he right length SHOULD work. Pictures forthcoming if it in fact works.

Overall this winds up being $80 per joint, $40 for the shaft, so $200 for a replacement, which is fairly expensive!

Expensive, but effective.

Each joint was 83.5mm long, cut the shaft to 204 to give 18mm on either side for the set screw to engage, giving a total(ish) length of 335mm. 

Once assembled on the car, I had to loosen the set screws to allow the shaft to come almost all the way out just to get it together, but it seems to all be within tolerance and seems fairly safe!