At what point is it time for prop repair?

Any damage will create a loss of efficiency, which turns into slower speed, and more fuel consumption. If you potter around this won't hurt too much, if you plane then it will.
 
....and when the bank balance will allow for a lift out, props repaired and then the vessel put back in the water.... :-)
I'm not sure to see what you mean.
Doing (or not) any job on a boat (or a car/house/whatever) is always subject to being able to afford it.
If you are aware of a nice place for living on planet Earth where this ain't true, I'm all ears... :)

Oh, and just in case it wasn't clear, I wasn't suggesting to change/repair the props because of a speed loss of one tenth of knot. But if the efficiency loss is relevant, doing nothing can well be a false saving.

Btw, I forgot to mention: increased vibrations can definitely be another alarm bell.
 
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