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Old 07-22-2010 | 08:59 AM
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Lnewqban
 
Joined: Apr 2007
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From: South Florida
Default RE: Wrong Drill Jig

First, I would return that drill jig to TroyBuilt, asking for a refund plus a compensation for the damaged propeller.
If they stated that the drill jig was good for your engine and it was not, THEY have a problem.

If there is no success that way, then, I would plug the holes with wood dowels and carpenter glow, which is soffer to redrill.
Then I would use the engine prop six hole washer as a drill jig, using a proper diameter central shaft or bolt for perfect centering.
I would drill the first hole (only one), on the same spot, starting with very small diameter bits, since the drilling will tend to deviate away from the new dowel.

Once that first hole is complete and correct respect to the center shaft or bolt, insert a bolt or dowel (tight fit) into it.
That would eliminate any accidental angular rotation for redrilling the rest of the holes.

Repeat the drilling for the rest of the five holes.
For better results, drill each hole half way in and then flip the prop hub and do the same from the other face.

I believe the propeller will not be weaker if you do not redrill in the space between the existing holes.

Best luck!