Years back I had the same problem almost. The splines on the shaft were gone, so we took the splined end of the shaft and cut 1 edge off (where the splines were bad) and then welded the inside of the crank where the shaft fits in it. Then we ground it square and flat to match the shaft. we put it back together and I used that motor for the next 12yrs. I think it was a 100hp.
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Tis better to be quiet and thought a fool than open your mouth and prove it!!
1991 V-20 cuddy I/O 350 volvo duo prop, 1998 15ft Grumman 9.9 Johnson 
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