Repairing Shaft?

Chip I did press in a new bushing but with a new 3/4 shaft it was just to tight so I use a 3/4 reamer and now that new 3/4 shaft fits perfect and I believe has just enough rm for some oil.I wish that maybe I would have turn the OD on the old shaft pictured just a cleanup pass then see if it would fit.But I did not think of that plus I was thinking of making a new shaft but then I would need someone to mill a key slot.
Right now as I measure on the very end its .750 but as I move towards the shaft its at a slight taper but only .004 plus has ridges when moving the finger across it.
 
i've done lots of repairs on electric motor shafts of a similar diameter and with key slots, my preferred method is to tig weld the shaft over size and turn it down to size on a lathe, use metal file to clean the slot or an angle grinder with an cut off disc, for quick jobs i even mig weld them but that puts a lot of heat in them.
 
Guys I thought I would pick up where I left off on this thread repairing shafts.I did get that shaft in the upper post make but it was a press fit and not the heat/shrink fit.It started out to be heat/shrink but did not work out.
Anyway I did make another shaft which is for turning the lead screw.As you can see in the pick the original one is kinda eat up from dry running and long after the shear pin snap off.This one shaft took me couple days to make due to me over shooting the OD at my first try,and several times having to rechuck the part and adjusting the chuck to true it up which I did get better at that.Something so small took so long but I have to say that I enjoyed making it.Now my only problem is figuring out how to cut for a woodruff key without a mill and a cutter.
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i've used round DIY woodruff key, simply drill 2-3 holes in line and use an old drill to make the woodruff keys, its always worked for me.
 
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