It is easily possible to modify the K&B 7.5 lower unit's prop shaft, bushing & Cable housing to make the unit bullet proof.
1. Remove the 1/4" wide leaded teflon bushings. Machine a Bearium metal bushing that extends beyond both ends of the housing. If you are using the stock K&B prop shaft, the bushings ID should be .2472" X .694" long. A .031" thick surface is machined on the back end for the teflon washer to bear against. Use a light press fit & #609 Loctite to hold the bushing in the housing.
Note: The original new leaded teflon bushings will allow a .251" shaft to pass through. Since all the K&B shafts measure .247"- OD, a brand new unit already has .004" total clearance before you run it.
2. Machine a new stainless steel drive dog that fits the .185" OD prop shaft. Use two 6-32 cone point set screws with #271 Loctite. The cone points should match cone shaped cavities on the prop shaft. I never use a flat surface.
3. Machine .062" thick teflon thrust washers that fit the .185" prop shaft. Assemble all the pieces.
4. Replace the teflon cable housing with a rigid wall brass tubing. Rigid wall brass tubing can be bent without annealing by using Cerro Bend metal. Cerro Bend, which can be melted at 212 deg F in a small container, is poured into the tubing that has been plugged on one end. Before pouring, coat the inside of the tubing with mineral oil. The Cerro Bend will not adhere to the inside of the tubing when it is melted out after bending. The Cerro Bend does not shrink when it hardens. This allows bending without any kinks, even if the radius is very small.
5 Add a grease fitting to the lower unit which matches a hole in the rigid brass tubing. Use a #2 white grease with a minature grease gun to lubricate the cable, prop shaft & the bearing at the upper end of lower unit.
6. Close off the front two holes in the bullet of the lower unit. When the engine is running, grease will travel down the cable & lubricate the prop shaft assembly.
If you desire to replace the soft shaft with a hardened shaft, use O-1 tool steel. Machine to size, harden by wrapping in stainless steel & then temper at 550 deg F. Tempering can be done by color providing the steel has been physically & chemically cleaned. The correct temper color is gold.
Note: A broach to make the .1562" square hole in the front of the prop shaft will cost approximately $125.00.