Replacing my column and the old column had a 1" output shaft at bottom. New one has 3/4" so had to get two new u-joints and intermediate shaft. The old intermediate shaft had u-joints pinned and then welded all the way around. The new shaft has splines but no flat spots or reliefs to hold shaft in place. I'm concerned if I just tighten up the set screw that it could wear a bit and the shaft can slide all the way into the u-joint. This would cause the joint to bind and the steering would lock up. Not good! I can either drill a small relief in the shaft where the set screw goes or weld a couple spots at the end of the joint to the shaft. It would be similar to the old shaft but don't think I need to weld all the way around. I like the welding idea better than drilling a relief. I just think it would be more solid with no possibility of slippage. Would there be any down side to welding, other than being pretty much a permanent deal? If a u-joint goes bad I'd have to replace the whole intermediate shaft again but that is not likely to happen.