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 - Usin Your Implements: Bucket Loader - by Curtis Von Fange. Introduction: Dad was raised during the depression years of the thirties. As a kid he worked part time on a farm in Kansas doing many of the manual chores. Some of the more successful farmers of that day had a new time saving device called a tractor. It increased the farm productivity and, in general, made life easier because more work could be done with this 'mechanical beast'. My dad dreamed that some day he would have his own tractor with every implement he could get. When he rea
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