Another possibility for an "off the shelf" solution...
http://www.mcmaster
or if you'd rather have a flex coupler:
http://www.mcmaster
These clamp-type couplers work real well for plain shafts. No keyway needed. The fit tolerance is fairly critical, but they are easily bored to fit if you have an off-sized shaft. You might get away with clamping it right over the OD of the splines. The "teeth" would bite into the bore a little and give some extra traction.
As to the vibration concerns, when using rigid couplers, a simple way to assure alignment is to install and tighten the coupler before tightening down the motor bolts. Spin it with the mount bolts loose and see if the motor wobbles. If it does(perhaps due to the OD of the splines not being perfectly concentric with the shaft) try loosening and re-clocking the coupler till you find a sweet spot.
Flex couplers make it easier but cost more. They can also provide galvanic isolation, important if it's going to sit in saltwater. Of course the motor/mount would need to be isolated too in that case. Probably not as much of a concern with an outboard vs. inboard.
Good luck. I always wanted to try an outboard conversion, but haven't got around to it yet. Please let us all know how it works out.
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