Axsail
FINDINGS LIBRARY · UNDERWATER GEAR

Damaged boat propeller: bent blades, nicks, a spun hub and how surveyors write it up

UPDATED 11 NOVEMBER 2026 · 3 EXAMPLE FINDINGS · 2 SOURCES

How to inspect a propeller for bent blades, nicks, cracks and a spun hub, when to repair and when to replace, the repitch limits for bronze and stainless, repair costs for aluminium and stainless, and three example findings graded A, B and C.

AT A GLANCE
Damaged propeller
USUAL GRADE
A for a cracked blade, a spun hub or vibration on the sea trial after a strike. B for bent blade tips or nicks that need a propeller shop. C for burrs and light leading edge damage you can dress with a file
FOUND WITH
Turning the propeller by hand with the kill switch out, running fingers along the leading edges, sighting the blade tips and feeling for vibration on the sea trial
JUDGED AGAINST
Discover Boating's repair or replace guidance, and BoatTEST's repitch limits: 3 in for bronze, usually 2 in for stainless
REPAIR COST
USD 100 to 150 to repair aluminium, USD 200 to 400 for stainless, USD 400 to 700 for a new stainless propeller, per Discover Boating

A propeller strike rarely stops at the propeller. Discover Boating says a damaged propeller is likely unbalanced and can cause vibration, and that after a hard strike the shaft should be checked too.

How to inspect it

Discover Boating says to take the kill switch out, put the engine in neutral and turn the propeller by hand. Look for bent blades and nicks in the leading edge, and run your fingers along the edges for burrs. BoatTEST adds cracks, and notes that galvanically corroded bronze becomes brittle and prone to cracking.

On the sea trial, vibration that wasn't there before is the sign. A boat that's slow to move under throttle may have a spun hub.

Repair or replace

  • Aluminium. Discover Boating says replacement may be more cost-effective, and BoatTEST that aluminium props usually aren't worth repairing.
  • Stainless. Repair often makes economic sense, per Discover Boating. BoatTEST puts the repitch limit at usually 2 in.
  • Bronze. BoatTEST calls replacement a last resort, and puts the repitch limit at 3 in for a propeller in as-new condition.
  • Spun or damaged hub. BoatTEST says replacement is the best option. Discover Boating says a shop can usually replace a spun rubber hub.

BoatTEST warns against straightening a propeller yourself. A shop scans it and checks it for cracks with dye penetrant. Bends are straightened with heat.

Damaged propeller: example findings

The same defect written up at each grade, the way Axsail writes it from what the surveyor says on board. The grade follows what was found, so use these as wording, then grade what you see.

UNDERWATER GEARA
Outboard propeller, stainless 3-blade

One blade bent at the tip and cracked at the root. Heavy vibration above 3,000 rpm on trial.

Recommendation: Replace the propeller before the vessel is next used, and have the propeller shaft checked for straightness by a dealer.

UNDERWATER GEARB
Starboard shaft propeller, bronze 4-blade

Two blade tips curled and leading edges nicked. Slight vibration at cruise.

Recommendation: Have the propeller repaired and balanced by a propeller shop within 12 months, and check the shaft for runout.

UNDERWATER GEARC
Outboard propeller, aluminium

Small burrs on the leading edges of two blades. No bends.

Recommendation: Dress the burrs with a file at the next service.

ASafety. Safety or compliance deficiency. Fix before the vessel is next underway.
B12 months. Deficiency that needs timely attention. Fix within about 12 months.
CRoutine. Note or observation, cosmetic or maintenance. Routine maintenance at the owner's convenience.

What fixing it involves

Job Cost, per Discover Boating
Repair an aluminium propeller USD 100 to 150
Repair a stainless propeller USD 200 to 400
New stainless propeller USD 400 to 700

After a hard strike, Discover Boating says to have a dealer inspect the shaft: a bent shaft must be repaired or replaced. BoatTEST adds that the slightest runout at the shaft or coupling causes vibration.

Photos to take

Each damaged blade edge-on, and the hub with its stamped size. With Axsail, read the stamped diameter and pitch aloud and they go into the finding.

Frequently asked

How much does propeller repair cost?

Discover Boating puts aluminium repairs at USD 100 to 150 and stainless at USD 200 to 400, against USD 400 to 700 for a new stainless propeller. It says replacing a damaged aluminium propeller may be more cost-effective, while repairing stainless often makes economic sense.

How far can a propeller be repitched?

BoatTEST says a bronze propeller in as-new condition can be repitched up to 3 in, and stainless usually 2 in at most.

What is a spun hub?

The rubber hub between the propeller and the shaft has slipped. Discover Boating says the sign is a boat that's slow to move or doesn't move under throttle, and that hubs can deteriorate with age even without a strike. BoatTEST says a damaged or spun hub makes replacement the best option.

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