Hi and THANKS for all the feedback,

I'm sure it was either me (most likely) or bad equipment. As I said, after using the drill press, I looked into the new hole and noticed a "Lip", I then put the prop back in the spinning reamer and pulled against the lip just enough to get rid of it....stupid, stupid, stupid.

Lesson learned, after stay up till 3am, DONT ream a new prop the next day.

Now on to the right way....The reamer from GP ( http://www3.towerhobbies.com/cgi-bin...?&I=LXEGH7&P=7 ) has a weird transition point at each step. It’s FLAT! There's no "slight" beveled cutting edge to ease the way for the next size. After 15 mins by hand is the reason I gave up and went to a drill press (that I admit wasn’t set up 100% before hand for this...again, NOT after staying up till 3am...gezzz)….. so, just man up and go by hand starting at the back or make sure the drill press table is 90 degrees to the reamer and go SLOW? And IGNORE the LIP!

Tx