Thanks mate!
Its not a problem with the hull, checked all that.
Lets just say it was all my fault!

Funny you should mention abot boiling a wood prop! When I used to make timber bows one trick to stop some timbers from splintering and to strengthen it for much better 'spring' was to soak it in sea water. Once re-dried the salt is combined with the timber on a cellular level internally making for higher tensile strength, so much so that some softwoods could then make quite nice bows.</p>