We realigned the engine/shaft. Moved the engine to starboard approx 3/32" and the forward end of the engine raised approx 1/16". Was going to remove the flex coupler and match the ends metal to metal but found that that would have been male to male. The flex coupler makes it male to female. So, relaigned to the flex coupler. Got it to within .002".
When we started the engine, we still had noise in forward but at a different rpm range again. In reverse the noise disappears. At this point I'm beginning to think that what we are hearing and even feeling a bit is water noise that we had never noticed (I'm having a problem with that though since it is rather hard to miss). After we get this other issue (the mixing elbow & most of the cooling water going straight to the mufflers instead of the mixing elbow) settled, we'll take her out for a run in the harbor to see how this older (orig?) prop works vs the newer (machine?) prop. Might end up putting the machine prop back on.