Wanted to share all what we did and the outcome. At first haul out, found that the shoe was a little loose and found some scraped paint on the shoe where the bottom of the rudder rubbed on the shoe when turning the rudder. They tightened the bolts on the shoe and raised the rudder at the rudder post so the rudder would clear the shoe. That didn't fix the problem. Hauled it again to change the cutlass bearing. Found the hose supplying cooling water to the cutlass bearing needed replacement, replaced the drip seal on the shaft log since it was all apart, found the bushing/ cutlass bearing on the shoe where the bottom rudder pin attaches had become elongated so was replaced, added a shim between shoe and rudder pin, balanced and tuned the prop, and repacked the rudder post. They supposedly aligned the engine and checked that the shaft was in spec but we were not present for this.
Went for the sea trial and reached 3400 RPM (if tach is accurate) at WOT. Was only out for 10 minutes and the vibration and loud growling noise were gone. Thought all is well but on our 5 mile trip back to the marina, at anything above 2000 -2200 RPM, the engine noise seemed louder than usual, and seemed to be centered above the cutlass bearing and shaft. We even commented that if we cruised at speed for any length of time that we would need ear plugs. Only had the boat out a couple of times before this happened and didn't notice excessive engine or running gear noise.
Any ideas why it is so much louder after we had all of this work done? Is it normal noise due to break in of a new cutlass bearing, or do they need to recheck the engine alignment? They did not check the torsion damper. Again, no vibration, but just pretty loud when running. Thanks to all!!