A few months ago, I put on new tie rod ends (L & R) and an inner tie rod on the driver's side. Ever since then, the tie rod grinds into the inside rim of the wheel when I cut the steering wheel 100%. (I confirmed this by noticing a groove ground into the tie rod end shaft).

Is this an indication of bad shocks/struts (which is very possible, given the age), or could they have sent me the wrong tie rod ends (too long)?

Did I do something wrong on the tie rod install?

 

Did you have an alignment done ?

 

Yep - sure did. The grinding continued after alignment.

 

Does the tie rod end look really bulky ? I cant really see how this could be happening.

 

I *think* I remember comparing the TRE's side-by-side before replacing it and I think I remember them being identical.

To answer your question, the TRE did not appear bulky - it looked pretty normal.

When I was doing the timing belt job, the car was on jack stands for over a month - could having the wheels suspended that long done something to the suspension, (which very well could have had considerable age on it)? The car doesn't currently appear to be sitting too low, but I could be wrong. (if the suspension is shot, could this be causing the wheel rim to touch the TRE?)

As soon as I get a minute, I'll snap a picture of the TRE and the front end...

 

I think you replaced with the wrong part. You probably replaced the part for the other side. I did this once and switched the tie rod ends. Just look at the other side (one without the problem). You should be able to see the clearance when you steer the wheel.