Can't have anybody falling through the handrails

 

Here are my steering shaft ends that I have now. Both ends have knuckles on them. A piece of 3/4" tube slides perfectly into the camaro shaft. I can drill a 1/2" hole into the 3/4 tube and bolt it right into the camaro shaft. The HHR shaft opening is smaller, so I'm gonna take a piece of 1/4" stock, cut it to fit into the HHR shaft, bolt it into the hhr shaft, then weld it to the tubing.

 

Ratty
That Camaro shaft has got to go. Using the Jeep shaft gives you u-joints to work with and is collapsible if need be just like the Camaro.
Bar stock is a better choice for the extension, but it will have to be supported in the middle someware with a Heim joint style bearing pedestal.
By the way plug up that open port on the steering box. Don't need water in it.
Edit:
The more I look at the picture it looks like there is going to be a bind issue at the firewall end. Use a wood dowel/broom stick and run it from box to wall. Take a look at the angles.

 

For steering joints look here https://www.borgeson.com/xcart/home.php, or here Steering Universal Joints

 

Thanks for the info and resources!

 

I wonder if you can flip the boot 180 degrees and line up the shaft better or get a better line directly to the stub spline at the bottom of the EPS motor

 

Which brings up; how do you propose to deal with the computer part of the power steering?

 

Can I remove the power steering fuse? What if I keep it hooked up, would that reduce the effort needed to turn?

 

I forgot you had a PS pump. pulling the fuse should work, assuming the BCM is going to be bypassed. You planned on rewiring the old fashioned way, right. Turn signals etc.

If you remove any of the nodes on the CAN bus the bus won't work right.

 

I've left the entire wiring harness intact. I got a ground junction block I'm gonna use to reconnect all the grounds on the harness. I did a test a couple weeks ago, everything worked as normal (blinkers, headlights, brake lights, turn signals, radio). My dash was reading reduced engine power and whatnot, but everything worked as it normally would. Someone said the bcm and ecm were dependent on each other so I'm leaving it all connected.