I've got to agree with George, the ways he has mentioned are the best ways to get it done. That said, as heavy as the shaft is, and as short of an area as you need to built up, and the diameter of the shaft, I don't see whay you can't do it by hand if all else fails. Personally I'd be more worried about taking the hardness out of it, as I assume the splined area is at least case hardened, than I would warping anything. That being the case, I think with a proper preheat and cool down you could lay a series of overlapping beads, parallel with the length of the shaft, and get the required buildup. If your worried about warping it start in two places, on opposite sides, and work back and forth until both build up areas meet.
One thing I will caution about, from experience, is that rehardless of what you do machine the area your repairing a bit undersized before you build it up. If you don't do that you'll be attemping to cut the new threads into the root of the weld. I have seen that cause problems, especially when cutting finer threads, if any hard spots happend to develop between the base metal and the weld at the fusion point.
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Today's Featured Article - Old Time Threshing - by Anthony West. A lovely harvest evening late September 1947, I was a school boy, like all school boys I loved harvest time. The golden corn ripens well and early, the stoking, stacking,.... the drawing in with the tractors and trailers and a few buck rakes thrown in, and possibly a heavy horse. It would be a great day for the collies and the terrier dogs, rats and mice would be at the bottom of the stacks so the dogs, would have a busy time hunting and killing, all the corn was gathered and ricked in what we c
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