Gordon, if you have got all the U/J's in the correct orientation and you are sure they are correct, loosen all the pinch bolts on the splined ends then ease the fittings so they can slide on the splines of each associated shaft. How does the steering function after this. If it works freely then try adjusting the shaft positions on the splines to see if you can achieve a better position which will allow the U/J's to not foul the inner wing.
It's vitally important that all U/J couplings are in the same orientation so when looking at Richards picture and at the U/J he is showing if you follow the shaft down to the rack each of the U/J's should be in the same plane. Come back to us when you have tried this procedure.
If the U/J's are not in the correct alignment the whole shaft when being turned as one unit will not follow the same axis of rotation and this could also cause the interference you are suffering. There is also another U/J inside the car directly behind the steering wheel! If the rack has at some point been removed for service was it removed by splitting the U/J on the short shaft immediately attached to the rack and not at the splined shaft of the rack itself then incorrectly refitted out of phase? The rack mounting blocks, alloy, to the crosshead are front and back different sizes. the rearmost element of the two pieces is larger, or deeper to be precise. If these were returned the wrong way around then this would shorten the distance of the rack towards the steering shaft and create longitudinal pressure to the shaft. I have also seen cars where the blocks were assumed to be the same and one side was correct and the other one not leaving the steering rack misaligned.
Of course it's hard to make a diagnosis without seeing the car and unfortunately you are a long way from poping over to have a look. Stand back with a cup of tea and start looking at the car for misalignment issues. inner wings to bullkhead, wheel positions to bodywork, Look at the crosshead, it should be square to the car, at right angles to the chassis. the axle tubes parallel to each other with the merest hint of a slight up flex of the lower tubes. Fundamentally, are both sides of the car a mirror image of each other dimensionally? Lastly at this time measure each side of the car wheel centre to wheel centre to check symmetry.
Martin.
