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There is no real disadvantage to using steel bar for a new propshaft other than you know its going to rust wherever its not buried in grease.
I used to make them out of 12L14 steel because it machines so easily, but it’s far from rust proof. You could use either cold or hot rolled steel bar if you want. I have switched to 303 stainless for most of my propshafts now. Its good and strong, rust-proof, and the easiest grade of SS for me to machine.
Brass is the easiest to machine, but plain 360 yellow brass is a bit too soft for propshafts, but its fine for a motor that you know isn’t going to run very much.
FWIW I have a bin where I keep the brass driveshafts that I sometimes find in Evinrude rowboat motors. They almost always have a twist in them, so I make new ones out of stainless….. but they are good for making brass drifts out of, as well as teaching other members about some of the weird things that happen with rowboat motors.
Thrust bearing – You could use Delrin, I guess….. or you can use a piece of hardwood dowel. The lignum vitae is just a real dense type of wood, so you could use your imagination for some sort of substitute. If I get desperate I just cut another piece of bearing bronze down and shove it down to the end. I sometimes see little packets of those wood thrust bearings at the club events like Tomahawk. I always grab them if I do run into them. Most people don’t know what they’re for, but most likely wouldn’t have a use for them if they did. I spose I could hand them out and say “here’s a piece of black licorice, you’ll love it” and sit back and watch what happens when they try to suck on it……..
Hope it helps.
Best,
PM T2
He's livin' in his own private Idaho..... I hope to go out quietly in my sleep, like my grand-dad did..... and not screaming, like the passengers in his car...