suggestion for removing a stuck prop

Good news!

Next question: how to prevent prop getting stuck next time?

Drill and tap holes in the aft face of the prop. Then a simple plate with the same pattern of holes + appropriate set screws, and it's easy to pull it off. Saves all this nonsense with heat and hammers.
 
Drill and tap holes in the aft face of the prop. Then a simple plate with the same pattern of holes + appropriate set screws, and it's easy to pull it off. Saves all this nonsense with heat and hammers.

That makes it easier to get it off when it gets stuck. The question was how to prevent it getting stuck.
 
It's on a taper, it's meant to stick! Do not overtighten when fitting.

Dead right, the key is just a locator, the drive is taken through the matching tapers.

I saw a large prop a few years ago in Gosport Boatyard removed by the owner using a rope and bar as a Spanish windlass. I was doubtful it would work, but the pullers available would not fit inside the rudder and cutting one down was not an option.

The nut was left on, the rope passed around the root of all 3 blades, led behind the steel rudder and tied off. The bar was inserted and the rope twisted as tight as possible and held. Another guy whacked the boss with two hammers, one each side and at the third hit it came off the taper. IIRC, the wheel had been tied off central so the rudder was not pulled to one side.

You never stop learning in this life!
 
Heat is good, even better if you chill the whole thing thoroughly first so the shaft shrinks; then heat the prop quickly and use puller, hammers, or whatever, quickly before the shaft gets warm.
 
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