Well said Skipper-Stu.

The two issues I raised however, were directly related to the original post:

In probably half a dozen cases out of 100's over the past 40 years I have come across a prop that simply 'stripped' even the biggest claw puller. Probably age and over tightening in the first place caused the siezure. That is where the trusty multi studded monster I made gets the job done. Secondly I have come across a few more than a half a dozen cases where the Shaft & Prop tapers were not the same. Only maybe a thou or so out, but never the less that taper as you say 'should' do the work. If it does not the thing will probably work loose in time, even with the key and castleated split cotter fitted. A key that is loose in either keyway can also be considered unsafe. (and that happens a lot).

Another hard earned lesson I have picked up over the decades is to leave the puller on for a few hours and heat the prop core, occasionally squirting release gas on the joint. (and possibly water on the cutlass). Sometimes you walk away from it for a cup of tea and with an almighty bank the thing plops off.

As a consolation to the originator of this thread "the odd one in a hundred is an absolute swine".

Cheers

John