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#31121
DAN ANDERSON
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    On the lower end of the shaft if you decide you can drop the shaft further into the case, you can just under cut the shaft like it is at the top? That way you don’t have to try and match the splines. If you have a way to turn the shaft (big drill, drill press) and a good file it shouldn’t take too long to file the shaft down to the bottom of the spline depth. Then the shaft diameter will pass into the pinion gear. I know you don’t want to go back to the machine shop! Wish I had it up here! My son has a lathe and wouldn’t take but a minute to cut it for you. That’s how I would handle it. OMC did things like that all the time. You can go back and make another impeller key just offset all the way to the top of the impeller. You did it once, you will be better at it this time. Just some ideas off the top of my head for what I understand the problem to be.

    Dan in TN