Quote Originally Posted by HotWater View Post
That circled area is the end of the old slot. We cut the shaft and extended the slot. It shows that the key rolled or tilted a little in the slot. Would a ball end mill slot with matching key eliminate that or be worse?
Well, you may have extended the life of the shaft. Like Westernaero said, that slot has seen some stress. Being it WAS the end of the slot makes a lot more sense. Now that its in the middle of the prop, its not nearly as likely to fail there. Not say it can't, but I have never seen a shaft that didn't fail right in front of the prop.