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Ok first off sorry no pic.
I have a November 69 vette, considered "late". The rag joint connection splines are 3/4 way round but the spline on the steering box is all the way round. When i look at the rag joint it almost looks like they were there at one time, do you think they rusted out over 43 years?
Thanks for the pic. I will have to upload one,the one you show does not go all the way around as you stated and has a clear straight place to slip onto a corresponding shaft. Mine however has what appears to be splines all the way around with the exception of about 1/2 inch or so where the splines look like they were but are gone now. Oddly the steering box splines go all the way around. I guess I'm asking if you guys believe 1/2 inch of the splines could have rusted off over 43 years?
In a word, "No". A few of those splines would not have rusted away. I would suspect that the steering box was changed out [sometime in its past] and the shaft on the new box had splines all the way around. The installer may have ground out the flat in the rag joint so they could be assembled. If so, it would have been better to locate the center position of the steering box and grind a matching flat on the shaft.
Just rebuilt the rag joint (steering coupler) in my 69. My VIN is close to 15000, the car is considered early as far as the coupler is concerned. My steering box shaft and coupler have full round splines, no flats. Late 69, 70, and on had box shafts with flats and updated corresponding couplers with flats. The flats were added to make centering easier.
I suspect your car may have an original early style box and coupler, could be left over early parts just used later in production. The coupler splines were designed to wrap around the box shaft. To obtain the "wrap" the special pinch bolt must be very tight. If the bolt is not tight there will be movement between the spline surfaces which will cause wear. This could be a mode of wear that have made your splines in the coupler very shallow.
I could not find a replacement coupler for the full round splines on my steering box. I did, however, find the Dormin 31000 rebuild kit which worked perfectly. I reused the shoulder bolts from the original coupler. The kit does not include shoulder bolts, just standard grade 5 bolts. The shoulder bolts make a better joint as the rubber is not deformed and will not loosen with time.