Must say that prop did not look kosher to me! What did Aviation Engines have to say wrt the issue? Is it a bad batch of blades or something? Please let the forum know - might be other people affected.
As for the other question you asked - I was told by Piet De Necker that the Rotax exhaust after muffler can reduce your engine's power output by up to 3 HP.
warp drive prop & rotax 503
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