Not uncommon problem. Level of difficulty ranges from not so bad to IMPOSSIBLE, The last time I tried I wrecked prop, prop shaft and took a nip out of water pump.
IF you have access to a lathe with both headstock and tailstock chucks, I would suggest mounting the assembly in tailstock and drilling out the prop shaft up to the sheer pin, Prop shaft is NOT hard s9 this is doable. Not much more than first using a center drill and then drill with small drill, the slightly larger drills until done. Unfortunately, by time this method came to mind I had already trued a brute force method.
7 slits mean an Oscillator type water pump
Note that drilling the prop shaft destroys the least expensive part in order to save most of the rest. Set up shown whoulc work.given all the lathe items.
Louis
Note #2 A center drill is a special purpose drill used to drill a dimple in center of object held in chuck of lathe or mill. It is a short stubby body drill that will resist bending and wandering. Standard drills will then stare in center dimple and will tend to drill a straight hole in center. Drilling thru with progressively larger drills will enlarge the hole to point the last and largest drill will remove a thin shell of metal.
The 3/16 hard steel pin can be driven out and the prop shaft gear can be removed with some ingenuity and effort to give the tailstock chuck more purchase to keep the axis of prop shaft assembly in line with axis of headstock chuck. Once the center drill has established the center dimple the drill tends to keep things aligned.
.Further edit…the tool made from a couple items from scrap box and a lot of nuts and bolts worked on mildly stuck props, BUT, failed miserably when confronted with a REALLY stuck example. After cutting prop away from prop shaft the cause was revealed….rust swollen prop shaft had a grip on prop that that a 12 ton press could not budge.
Louis
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