Re: 35 hp johnson.prop
since that prop is toast(ing) anyway, due to the minor pitting, would you be willing to experiment?
I'm a big fan of vented props.. even though folks will argue they are for performance rigs with weight and deep pitches, it's my opinion that any engine can gain from them, allowing a higher pitch to be used on a rig requiring a lower one..
assuming that is a through hub exhaust, if you were to drill at the base of each blade through the casing with no larger than 1/4" holes (the base side of each blade nearest the gear housing, and on the blade side you can't see while looking at the prop from the exposed side of the hub), you will find your engine is capable of spooling up much faster...
the concept is to allow a 'controlled ventilation' by exhaust being spilled on the face of the blade, allowing it to slip.. the hydro force of water slipping past those vents as speed and surface tension on the vents increases closes them off when you reach planing speeds.. what it allows is the prop to spin more freely before forward movement happens, which allows the engine to reach it's power curve quicker.. think of it as your prop getting a running start at the water before it bites in fully..
the only problem w/ doing this is how the hub supports attach to the outer casing- if the holes you're drilling interfere with those flat stanchions, you can't tap it...
it sounds, based on your description, that your engine is capable of revving to the rpm range you need, but it would benefit from a lower pitch... the question is if that lower pitch is too shallow, and allows your engine to over-rev.. if you can reach WOT recommended by the manufacturer with the current geometry, then you are a prime candidate in my opinion to tap the vents.... and if it doesn't work? well, you're prop shopping anyway... and your next prop should be lower pitched, and slightly larger diameter to make the difference back up.
