lining up the rear sprocket with a ruler is absolutely fine,just take your time to get it right
i dont know many people who split their own chains.you will find yourself acumulating many different sized chains to accomodate different sprockets and "situations" (as you have discovered with your cross member).just keep hold of the chain,it will be of use at some point and get the correct size
as for the axle keyway,it difficult to say without actually seeing it but i know mine wasnt covered by maybe 50% so i just put some good tie wraps around the axle and keyway which does the trick nicely
others will have different opinions of course! :)
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