I wouldn't begin to change the good advice received here and that is not my intent.
I do want to point out though that using the same wood the prop holes can be filled with the appropriate wooden dowels and glued in place. I have always used the same glue the props are made with. Resourcinol 2 part glue. The glue bond is stronger than the wood itself is.
The prop can then be drilled for the new prop pattern. When I have done this it always try to geep as many of the new holes in the original wood as possible but sometimes there is just a little change or irregularity in spacing.
After redrilling the hub, the key is that even though the hub was drilled in a circle ya still have to reballance the prop.
Once balanced a similarly repaired prop has a good lifespan under normal use. I guess the caviet, is, What is normal use right?
I sure have fixed a bunch of em for folks in the past. With the new plastic props out and reportedly performing excellent, I just don't see much point in repairing an old wooden prop nowdays. There was a time when it made good financial sense to do so, but I suspect those days are long gone now.
Scotty :lol: