Well at least we have diagnosed the clattering noise, by using the problem solving technique of ruling out the other problems. It seems that the rear coupling is not true and it is bent. I am not sure if it was dropped at one stage, or whether it is out due do engine misalignment but it clatters and it is not rotating in true. The only real way of seeing weather this theory is correct is to take the boat out of the water again, then machine some of the end of the coupling off in a lathe to make it true, and then add a flexible coupling that between the existing one and the end of the shaft. Its a whole lot of extra bother, expense and frustration, but it is worth getting this sorted once and for all. The good thing is that I know know that the engine is in top working order and that the rebuild gearbox is in fantastic order as well. After this work the engine should be OK for years to come....cross fingers.
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