Greetings! From the pictures Joelq sent us, it appears that everything was installed correctly so I'm not 100% sure why the washers were needed, other than the snout interfering with something. Our bottom line for him is that there are a couple of other motor options that don't have the bump-out by the shaft, so we have changed our recommended motors for those pumps on our website. I sent him a couple of different options and noted on his order the issues he had as well as the fact that we recommended it for the NorthStar, so we are happy to take care of him in the future if anything happens and he decides to stick with the motor he has.
The motor shaft length from the mounting face is the same on both motors (the old one and the new VS one), so the addition of the washers is troubling since it changes the position of the impeller. Since many of the parts for this pump are difficult/impossible to find, we have cautioned him that a new motor is probably the
only option.
Our current variable-speed recommendation for Joelq is either the
2.7HP Nidec motor or the
2.7HP A.O. Smith (Century) motor so that will address any concerns with the horsepower. We are happy to send him whatever he prefers to make sure he gets everything working perfectly.