If you are set up to remachine the threads, could you machine a custom set of smaller diameter threads in the shaft, and machine a new custom nut. Or, even weld the ID of the existing nut and ramachine it. Welding on the nut has much less risk since the stress is much less of a concern in the nut and the distortion much less critical.
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Today's Featured Article - An Old-Time Tractor Demonstration - by Kim Pratt. Sam was born in rural Kansas in 1926. His dad was a hard-working farmer and the children worked hard everyday to help ends meet. In the rural area he grew up in, the highlight of the week was Saturday when many people took a break from their work to go to town. It was on one such Saturday in the early 1940's when Sam was 16 years old that he ended up in Dennison, Kansas to watch a demonstration of a new tractor being put on by a local dealer. It was an Allis-Chalmers tractor dealership,
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