I've had this issues as well on my 18' 23 lsv w/ stock wetsounds amps... another trick that seems to work is to mute speakers when starting.

It looks like you have about 1/4" or so to play with in the groove.  Did you try a BFH and a punch to try to drift the key forward a bit to unlock it from the prop and shaft?

Mapgas should expand the prop and theoretically could release the bind between the prop and the key/pin. 

Trying to remove a slightly damaged prop and I think the key is broken/locked.

I've gotten the prop most of the way off, but the last couple of inches are really tight. I'm using a puller and hammer and probably grinding the key over the shaft threads if I had to guess. I've tried sticking a small screwdriver in the key hole and hammering it either direction, no dice.

With the puller I'm past the point it can pull, so added a spacer but it's slow going. Going to try mapgas next, but I'm not sure it'll help since it's not "stuck", it's a busted key.

Any other advice? I'm trying to avoid drilling the key or cutting the shaft threads.....

3 hours ago, Slayer said:

Me too.  They called me this morning to advise me that my boat is in Grand Rapids getting gel coat repairs under warranty.  I was supposed to get it tomorrow, and now it's next week.  Not thrilled with this to say the least.  To @ahopkins22LSV and @MikeR397, I'm happy to hear you're pleased with how they're handling things for you.  I can't say the same.  My boat has been there since the last week of February and this is the 3rd time it's been held up.  Also, we do have Gull Lake and the Coldwater dealers in the state.  I've spoken with Full Lake and they've said they would service my boat if needed.  

I picked my boat up last night from the GR location as it was also getting warranty gel coat repair. It was done quickly and I was happy with the timing. They also summarized the boat while it was there and everything seemed business as usual.