Re: impeller stuck
I reinserted the impeller shaft with the key in place, put glycerine on the pump housing lip, seal gasket and impeller and bolted it all back together. I had an idea for inserting the impeller which worked pretty well - I put a zip tie around the impeller to hold the fins in (all leaning the right way) while I got it started into the pump. When the impeller fins were all started inside the pump housing, I clipped the zip-tie loose, rotated the impeller until it aligned with the key on the shaft and pushed it the rest of the way in -- worked pretty slick. A quick hour-long test run on the lake at slow and fast speeds yielded no leaks and temp at normal (180) the entire time. - Yeah! At one point after a fast run for about 2 minutes, I dropped it back to idle and pulled off the motor cover to check -- I noted a bit of noise that sounded like it was coming from the pump but it did not last more than a few seconds -- I though maybe it was just the new impeller seating into the pump - water had been running through for some time.
Again, many, many thanks to all who offered information, advice, and shared experience to this novice -- you all made my day!