BEngo

Could you get a needle gun in there?

Davall gears or HPC gears will make you whatever you need using an original as the pattern. They are quite quick and IME not too ridicilously pricey. They will also machine bores to specific sizes if specified when ordering. Bronze does not normally run well with unhardened steel, but does run well with hardened steel. Bronze on bronze is likely to gall, but can be done with the right ( different alloy in each gear) bronzes.

The pic looks like mechanical damage, with additional spots from inadequate preparation. To get a long lasting solution you will need to strip the affected area to metal and treat the rust, either with Fertan/Vactan/ phosphoric acid or by sanding disc then repaint with a full primer, undercoat, topcoats scheme.

P&S Marine at Bridgwater basin Cassio, Watford do grit blast and epoxy.

If running the pump 'out of system' do make sure there is water in the pump chamber before starting up. The impeller will not last long if run dry. Ideally you want the water in the bucket above the inlet and to fill the pipes as much as possible. A drill with plenty of grunt will be needed, and not too much speed. Attempting to wizz the impeller round at 2000 rpm will soon wreck it, or the drill will emit magic smoke.

Refurb kits are readily available on the web. The seal is not that difficult to replace, once you have the pump removed. On a par with changing a diesel filter I would say. Do you have a mechanically minded pal who can "help," or show you how? Letting us know your general location may prompt some possible professionals' details. Worth renewing the impeller at the same time.

How old is the boat? If it is modern, then the stuffing box and associated nipple are likely to be metric. An older boat is more likely to be imperial. What are the nuts for the gland follower- metric, or Imperial? The grease nipple should be the same family. I have not looked recently, but grease nipples were usually available as an assortment, for not much money. Combine that with the age of the boat and measuring the A/F dimension of the existing and I would expect to get a suitable nipple in a couple of tries. If you are cheeky you can then buy a 'one'off ', replace it in the assortment and return them for a refund 👹

Mang large outboards have a power trim facility so it can be adjusted to suit the speed in use, whilst moving. The goal is to have the propshaft centreline horizontal at all times.

The spacer ring looks like a die casting. If it is cast the groove is there to accommodate the shrinkage as the liquid metal first solidifies and then cools. Otherwise the ring will warp and/or crack... It is also convenient that it reduces the overall amount of metal needed. Kelvin J/K and the poppet valve engines' flywheels were cast with circular holes in the body for the same reason.

Looks to be a similar principle to flame cleaning.

Willowbridge in MK would be my suggestion. They can also lift it out if needed. Possibly Baxters at Yardley Gobion. Further North there is Stowe Hill, the boatyard at Weedon and the operation just past railway turn. Whilton might be a possible destination too- they might buy it off you, give it a coat of London White and have it southbound in short order🙄 Southward there is Wyvern, the Boat Shed at Tiddenfoot near Leighton and Bates dock at Bulbourne

Are the washers magnetic? Aluminium ones will not be. While you get some better ones, you could re-face Al ones by rubbing the seal faces on some 240/320/400 grit wet and dry on a ceramic tile or a worktop. Keep the wet and dry wet, with a drop of Fairy in the water. Rub gently and evenly in figure 8 patterns.

The ruins look a bit like either the ironworks at Kirtlington or the cement works which are nearby.( Not the later rail served cement works above Shipton Weir lock.)

After 4 years it should be fine, except for mechanical damage caused by things like shopping trolleys. Ours was initially done in 2010, (grit blast and Epidac coal tar epoxy, no Zn), checked and repaired then overcoated in 2014, 2020 and 2025 (SML epoxy). It is still in good order despite having done a lot of miles between 2010 and 2021.