Mitch,
Most out of balance problems seem often to be the hole isnt drilled in the middle of the prop. Sometimes the hole isnt straight as well, I have measured props with vastly different pitches on each blade because the hole was not straight! But if the hub isnt symetrical about the hole this generally isnt a major factor because the out of balance mass is so close to the axis of the prop. The bigger problem is the hole is probably then not in the centre of the prop.
I back-cut the prop, so it was not a stock prop that broke. I contacted the manufacturer, who said they believed the back-cutting was the factor that resulted in failure. While back cutting like I did would weaken the prop, I dont think that it should have broken as there was still plenty of blade chord length at the hub and plenty of blade thickness in the design. There was no casting flaws I could see. But also no radius between the blade and the hub, which is a stress rasier at the point of highest stress. I dont want to name the manufacturer as they have been quite helpful to me otherwise.
The boat was a Sprint 90 hull, running a modified A-90HP engine, Bolly P92 pipe and 50% nitro.
Ian.