Prop Shaft Coupler

[Stevek]

I am in the process of replacing my boat's engine. It is a different engine and tranny so they will have new mount locations. The new coupler is 1.5 inches longer than the old one and there is not enough room for it to be flush with the shaft. Two options, 1) cut the new coupler down and redrill the set screws or 2) let it stick out past the end of the shaft. It has a key and two set screws. My question is, Will letting it extend 1.5 inches cause problems? (extra torque on the key) Thanks for any thought on this. By the way, the new coupler is much beefier than the old one.
Steve

[James S]

Have you got any pictures Steve?
On the face of things....1 1/2" sounds like a lot....how much does that leave on the shaft?
What is the diameter of the shaft?
Can you slide/move the shaft to accommodate for the difference in length?

[Stevek]

No pictures right now. The old coupler is 2.5 inches long and only has 3/8 inch to an old 3/4 pulley ( from an old alternater system )then the stuffing box. As the boat is in the water, I am waiting to remove the pulley until after the coupler is installed and secure.

[Stevek]

Just resurfacing this question as I was hoping for some thoughts before this weekend
Thanks
Steve