Are the splines okay ???? Post a picture up if possible.
Don't bolt a sprocket onto the end of the shaft. That will never work.. It will just be torn off.
What is the bike and how is it meant to be held on ??
As it's already welded, then no doubt the splines are heat deformed and fused with the sprocket so grinding is likely to make a bigger mess and do more damage.
If the shaft is damaged too much then all you can really do is keep breaking off and welding on sprockets until you can get a new shaft. Just make sure you buy STEEL sprockets. And when welding. Allow plenty of cooling or you will damage the oil seal and that will just ruin your day even more..
If the splines are deformed, and if possible, then I suggest you move the sprocket over on the output shaft a little and then you can space out the read sprocket to match. Using shims, washers etc. Just make sure you use longer bolts.
If the splines are okay, fix a new sprocket and you can weld on the END of the shaft to stop the sprocket falling off.
To replace the shaft, you're talking a bottom end rebuild. Expensive and not to be done on a hostel floor...
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Did some trips.
Rode some bikes.
Fix them for a living.
Can't say anymore.
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