Kevin
I was replacing the entire V-drive, so there was no need to even consider saving the splined shaft. It sounds like you are planning to reuse your splined shaft however. Someone might have one they no longer need. It might be possible to have Walter remachine it. The jack-shaft is very expensive. I don’t remember what Walter wants but I think it was several hundred dollars. After installing the new splined shaft, I fund that no amount of tightening would properly secure the shaft so I drilled and tapped a hole and installed a set-screw with lock-tite.

If you want to get the drive-train to run smoothly, you must very carefully align it. This can’t be done until after the boat is in the water and may need to be tweeked once or twice. You can get it close on the hard and then fine adjust it after the boat has set for a day or so in the water and the rig is properly tensioned. If I get mine correct, it runs pretty smooth. There’s some vibration in my feet if I stand right next to the engine, but none in the cockpit and stuff doesn’t rattle when underway. The shaft must be true and the propeller in good condition.

Use a hammer and chisel to tap away any rust from the inside of the jacket. Replace the pipe plugs. Do a good job cleaning away any chips or they will clog the heat exchanger. Plan on at least 8-hours to clean the jacket.

Regards
Rich

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