I just measured the bore and shaft on one of my outboards. Bore on both ends measure out at exactly .375". The shaft, measured in the area contacting the bore comes out at .364" and .363". This means I have .011" to .013" of side to side play between shaft and bore. With the aluminum being the softer material, I am sure that it wears more than the shaft. But in order for it to have worn, it would have started with a bore closer to .365" in order to get a good fit with the shaft. That would just seem odd, however, for a 3/8" nominal shaft. And measuring the shaft at a location farther out where it is not bearing against the bore I do get the same dia. measurement (.364") so I am confident that the shaft has not worn. In other words, after measuring the bore diameter at exactly .375", I would have thought for sure this would have been good, since it is exactly 3/8".
Also, there is a machined step in between the bearing surfaces on the shaft measuring .352" dia. and .342" dia. Can this area be used to secure a teflon shim (.010" thick and .015" thick, respectively) instead of boring and resizing for a bronze bushing? It seems the bushing repair kits I've seen come with an expensive boring tool that can be used multiple times. I only need it for one time.
Any insight into this problem would, as always, be greatly appreciated.