Well it just got a ton more complicated.
At this time I would like to thank all the engineers of the world for making shit WAY MORE COMPLICATED THAN IT HAS TO BE!
I'm not sure if they still teach the K.I.S.S. method, but they should have a refresher!
That being said here's where I'm at...
It would require several new parts to be prototyped and made in order to fit the '12 column into the '05, as the clock spring will not swap.
Here is a list of everything that I would need to create in order to swap the columns.
1. Cut the '05 columns clock spring mount off of the '05 column, bore it to fit the '12 columns outer tube and tap some set screws to mount it up. I would also have to shorten the '12 column's tube to allow the wheel to mount as the clock springs have a different depth vs shaft length.
2. CNC a key way into the '12 column's shaft to allow the '05 clock spring to know where it is positioned or the ESP and vehicle stability program is going to freak. The '12 has no key way, it's pressure fit.
3. CNC the rear of the '12 columns shaft to a 0.5630 flat dia. on the top and bottom to allow it to mount to the '05 intermediate shaft.
4. CNC a mounting plate for the 12 column to adapt to the 05 placement.
All of the above can be done, but it would be a huge amount of time and development costs.
Some would give up and call it a day, but I'm not built that way!
It will be done and here is how.
I plan to keep the '05 column and clock spring. My '05 wheel will become a donor and be milled down to create an adapter for the '12 wheel. This will be easier than starting from scratch as I will only need to mill the outside splines and taper stop.
Since I have the '12 column I know exactly what the specs of the splines are and can mill the outside of the '05 wheel to fit the '12 perfectly.
This will keep the '05 and '12 splines perfectly mated.
1 part and done!
Here are some '12 shaft and '05 shaft pics.