I've not seen a star washer in the column before, only that split washer as in pic.
As orientation goes it's the big cup thing first which slides in the tube then the star washer which is meant to centralize the column rod, then spring and then the cancel cam

Ohhhh yep Marty thanks now I see, I think I know what the issue is. I have a new upper bush from burtons, that does away with the cup. Which means the star washer becomes surplus to requirements also becuase as you say that centralizes the rod in the cup.
 
I've got it now, thanks gents!

Big day around these parts! The car is back on its wheels for the first time since October 23! 
 
Shes offically a roller, and even better - the bolts for the tramp rods slid home with hardly any mucking about once it was at ride height! It's nice to get a win every now and then. 
 

 

 
But as with all things car related a win always comes with friends, because the front doesnt have the weight of the engine and gearbox to settle it, the front wheels clip the front of the guard ever so slightly when going lock to lock.

Looks like my caster adjustment with the sway bar mount was a little aggressive , so i'll need to pop down to the hardware store tomorrow and get some washers to space it back a little in the meantime so everything clears. 
 
Apart from that everything is booked for it to go back to the panel shop on Tuesday, it's been decided to leave the glass out of the back for now and they will mask up the holes.

What you could do as a temporary fix till the engine goes in, yes the washers are a permanent fix, though you could do simple shims from 3 or 5mm plate with an 18mm slot so it's a C shape similar to the door shims. You'll only need to back off the inch nut and slide the shim in and tighten back up. Just remember that they are there before you test drive it or they could fall out and cause a squidgoid effect on the front end !!

Thats a good shout, I could even just notch a few washers and do them 180 out from each other, will save the mess about of dropping out the swaybar until its back from the shop.

I've been working away a lot over the last two months and it looks like that's going to continue for a few months to come... you wouldn't think house paint has anything to do with the stupid stuff going on overseas, but the company I work for gets raw materials out of that area so here we are.
 
I've been doing what I can on the weekends, which isn't a lot to be fair but I am moving forward none the less. While the car is away I have been playing with more 3D printing stuff, and designed/printed a fan shroud. It's my first functional part printed in carbon fiber infused nylon!


 
It's been designed to take this brushless Davis Craig, it's cool that they give you every dimension so whilst I havent ordered it yet, I am confident it will fit just fine.


 
Due to my printer size I had to print it out in four parts and design in dowels and bolt holes to put it together. Even without the fan on it its already pretty solid, and with the nylon having a softening temp of like 150 degrees, I dont think there are going to be any issues with it living in the engine bay.


 
Next job is to design the "fappers" and get them printed and fitted on, I am printing them out of the same stuff but designing in a layer of rubber for a gasket so they make a good seal. 

Ok that took a few revisions to get right. Finally got it sitting flush though and opening smoothly.


 

 

 
Now I just need to print out three more and get some more rubber to attach to the back. The glue I used for the firewall blanket worked a charm. 
 

That's fab Mark.
I am envious of you guys getting into this technology.
Probably a dumb question but what are the 'flappers' for?

Yeah, you've taken to this technology really well . And here's me designing a simple bung for the steering column to bulkhead seal in tpu !!
I've got a printer with a 450x450x450 got to assemble it 1 day, had it 3yrs and still in the box !
My 'daily' printer is the regular 240sq which has been a great size so far.
What design platform and slicer do you use?

I'm learning freeCAD and still using tinkercad for these designs. For prep and printing orca slicer. Its been great fun learning everything.

The flappers help with airflow at highway speeds, thermo fans create turbulance at speed and reduce cooling efficiency so the flaps allow bypass and reduce the turbulence. The static pressure of the fan pulls them closed at slow / low speeds when the fan is pulling more air than the speed produces.

Most if not all modern cars that run thermos have them, gives you max cooling efficiency at slow and highway speeds.