Blog

  • Propeller Slip Theory Explained

    Theory

    Propeller Slip Theory Explained

    October 2026 · 7 min read · By Brian Rogers Marine Engineering

    Propeller Slip Theory Explained

    Slip is the single most misunderstood number in propeller selection. Here’s what it really means — and why 30% slip isn’t a problem for a trawler.

    Introduction

    Walk the dock on any Saturday and you’ll hear boat owners talking about prop slip. Most of them have one number in their head — usually a low one — and treat it as a measure of propeller quality. That’s not quite right. Slip is a theoretical quantity, and interpreting it correctly is the first step to specifying the right propeller for your vessel.

    In this article we’ll break down what slip actually is, how it is calculated, and what reasonable slip percentages look like for different vessel types.

    What is propeller slip?

    A propeller has a pitch — the theoretical distance it would move forward in one revolution if it were turning in a solid medium (like a wood screw turning in wood). In water, which is a fluid, the propeller does not move the full pitch distance per revolution. The difference, expressed as a percentage of theoretical pitch, is slip.

    The formula is:

    Slip (%) = (Theoretical speed − Actual speed) / Theoretical speed × 100

    Where theoretical speed is RPM × pitch / gear reduction, with the correct units — typically knots.

    Worked example

    Consider a vessel with:

    • Engine RPM: 2,100
    • Gearbox reduction: 2.5:1
    • Propeller pitch: 20 inches
    • Measured boat speed: 15 knots

    Theoretical speed = (2100 ÷ 2.5) × 20 ÷ 1013 × 60 = 19.9 knots. (The 1013 is the conversion from inches/min to knots.)

    Slip = (19.9 − 15) / 19.9 × 100 = 24.6%.

    Is 24.6% slip a problem? Depends entirely on the hull.

    Healthy slip percentages

    A properly matched propeller usually falls in these ranges:

    • Displacement cruisers / sailboats under power: 30–45% slip is normal.
    • Semi-displacement work boats: 20–30% slip.
    • Planing hulls at cruise: 10–20% slip.
    • Prawn trawlers at tow: 50–70% slip (because the boat is being deliberately dragged by its net).

    The highest-slip application is not a problem — a trawler at tow is intentionally working against the propeller. The slip number simply reflects that physical reality.

    Why slip matters (and when it doesn’t)

    Slip tells you one thing clearly: whether the propeller is loading the engine correctly.

    Too little slip (say, 5% on a displacement cruiser) often means the propeller is under-pitched or too small — the engine over-revs and never builds its rated torque.

    Too much slip (say, 50% on a planing hull at WOT) usually means the propeller is cavitating, the blades are damaged, or the engine isn’t producing rated power.

    Common slip problems

    If your slip number has changed over time, check for these:

    • Blade damage — nicks, bent tips, erosion.
    • Growth on the hull or propeller — barnacles especially.
    • Change in load — are you now routinely carrying more weight?
    • Engine not making rated power — fuel system, compression, turbocharger.

    Conclusion

    Slip is a diagnostic number, not a merit badge. The right propeller for your boat might have 30% slip or 5% — what matters is that the engine reaches rated RPM at wide-open throttle with margin to spare, and that your cruise point is in the engine’s happy zone.

    If your current propeller doesn’t do that, we can help — a measurement, a bit of maths, and a re-pitch or new design will put the engine and the hull back on speaking terms.

    Need advice on your boat’s stern gear or propeller? Call Brian directly on 0413 771 090 or use the contact form — we respond the same day.

    Read Next

    More from our workshop

  • Choosing the Right Propeller Size for Your Vessel

    Guide

    Choosing the Right Propeller Size for Your Vessel

    September 2026 · 9 min read · By Brian Rogers Marine Engineering

    Choosing the Right Propeller Size for Your Vessel

    A propeller is sized by four decisions — diameter, pitch, blade count, and blade-area ratio. Here’s how we make each one.

    The four size decisions

    Sizing a propeller is picking four numbers that work together: diameter, pitch, blade count, and blade-area ratio. Get them right, and the engine will spin at rated RPM at wide-open throttle (WOT) and burn as little fuel as possible at cruise. Get them wrong, and the engine will either labour or over-rev, the boat will drag, and your fuel bill will climb.

    Start with the engine, not the boat

    The engine data sheet gives you the two most important inputs:

    • Rated RPM at WOT — the propeller must let the engine reach this. Not 50 RPM short, and not 300 RPM over.
    • Rated continuous RPM at full load — your cruise point should sit here.

    From rated RPM, we divide by the gearbox reduction to get propeller shaft RPM. This is the number everything else is designed around.

    Diameter — the biggest single lever

    Bigger diameter = more thrust for the same RPM, up to the point where blade-tip speed goes supersonic (practically ~45 m/s). Diameter is limited by:

    • Hull aperture clearance (typically 15% hull-to-tip clearance).
    • Shaft-to-waterline depth.
    • Rudder clearance.

    Within those limits, pick as big a propeller as the hull allows. A one-inch increase in diameter is roughly equivalent to a two-inch pitch increase in loading effect.

    Pitch — matching engine RPM

    Pitch is the fine-tune. Once diameter is fixed by the hull, pitch is picked to make the engine land at rated WOT RPM. Rule of thumb: 2 inches of pitch ≈ 450 RPM. Over-propped? Reduce pitch. Under-propped (over-revving)? Increase pitch.

    Blade count

    More blades = smoother, less vibration, more thrust at a given diameter — but slightly less efficient. Common choices:

    • 3 blades: planing hulls, pleasure craft, maximum efficiency.
    • 4 blades: displacement cruisers, workboats, smoother at speed.
    • 5 blades: large commercial, trawlers, maximum thrust and smoothness.

    Blade-area ratio (BAR)

    BAR is the total blade area divided by the disc area of the propeller. A heavily-loaded (high thrust-per-area) propeller needs more blade area to avoid cavitation. Typical BAR:

    • Pleasure craft: 0.5–0.6
    • Fast workboats: 0.6–0.8
    • Heavy displacement / tugs: 0.8–1.1

    Worked example — 42 ft prawn trawler

    Engine: 300 hp @ 1,800 RPM, gearbox 4:1 reduction. Hull aperture allows 40″ diameter. We’d typically specify a 40″ × 28″ four-blade propeller in manganese bronze, BAR 0.75. At WOT, the engine should reach 1,800 RPM at tow with the net streamed. Cruise free-running at 1,500 RPM.

    Conclusion

    Propeller sizing is engineering, not guesswork — and the engine data sheet is the starting point. If you’d like a propeller sized to your boat, send us the engine and hull data and we’ll run the numbers.

    Need advice on your boat’s stern gear or propeller? Call Brian directly on 0413 771 090 or use the contact form — we respond the same day.

    Read Next

    More from our workshop

    Propeller Slip Theory Explained
    Theory

    Propeller Slip Theory Explained

    Slip is the single most misunderstood number in propeller selection. Here’s what it really means — and why 30% slip isn’t a problem for a trawler.

    How Your Propeller Affects Fuel Burn
    Theory

    How Your Propeller Affects Fuel Burn

    If your boat is wearing the wrong propeller, you’re burning diesel for no return. Here’s how to see it in numbers.

  • Stern Gear Maintenance Checklist for Owners

    Maintenance

    Stern Gear Maintenance Checklist for Owners

    September 2026 · 6 min read · By Brian Rogers Marine Engineering

    Stern Gear Maintenance Checklist for Owners

    A one-page checklist of what to inspect on every slipping — plus the five things that are cheap now and ruinous later.

    Why a checklist helps

    Stern gear problems rarely announce themselves. A cutless bearing wears gradually; an anode disappears quietly; a shaft seal drips a little more each month. The engines-on-top-of-engines mentality that keeps outboards running doesn’t quite fit inboard shafts, so this is a short checklist for your next slipping or your workshop day.

    Propeller — inspection points

    • Blade edges — look for nicks, erosion, bent tips.
    • Blade root — hairline cracks appear here first.
    • Hub — fit on taper, keyway wear.
    • Nut and split pin — torque to spec, new split pin.
    • Zinc anode on hub — replace at <50% remaining.

    Measure diameter and pitch of each blade. Variations of more than 1° blade-to-blade mean a trip to the propeller shop.

    Cutless bearing — the wear test

    With the propeller off, grab the shaft at the stern tube and try to lift it. A good cutless bearing lets the shaft lift roughly 0.5–1 mm. More than 1.5 mm, and the bearing is worn. Replace before the next trip — a worn bearing lets the shaft whip and will chew the shaft and the next bearing in minutes.

    Shaft seal

    • Face-type seal: Carbon face thickness > 3 mm. No weeping with the shaft turning.
    • Stuffing box: Re-pack annually. The shaft under the packing should be smooth.

    Shaft itself

    Run a dial gauge against the shaft near the coupling. More than 0.1 mm total indicated run-out and the shaft is bent. On the taper, check for fretting — a sign the propeller nut has been loose.

    Coupling and alignment

    Check the engine-shaft coupling for a 0.05 mm feeler gap all round. More than that and the alignment is out — re-shim before leaving the slip.

    Anodes

    Shaft anode, rudder anode, hull anode. All three should show less than 50% consumption at every slipping. If one is going fast and another barely at all, there may be a bonding problem — investigate before the next haul.

    The five cheap jobs

    1. New propeller nut split pin — $0.50.
    2. New shaft anode — $35.
    3. Fresh grease in grease-type seal cup — $10.
    4. New propeller key if any sign of wear — $25.
    5. Fresh paint on bonding wires — $5.

    Together: under $100. Skipping any of them has sunk boats.

    Need advice on your boat’s stern gear or propeller? Call Brian directly on 0413 771 090 or use the contact form — we respond the same day.

    Read Next

    More from our workshop

  • Marine Propeller Shaft Materials Compared

    Materials

    Marine Propeller Shaft Materials Compared

    September 2026 · 7 min read · By Brian Rogers Marine Engineering

    Marine Propeller Shaft Materials Compared

    Aquamet, 316, bronze. The right choice depends on your use case — not the price list.

    Introduction

    Pick the wrong shaft material and you’ll know within three seasons — either from a corroded shaft, a bent one, or an unnecessarily expensive stern-gear bill. Here’s how to choose.

    Aquamet 22 — the premium choice

    A specifically marine-engineered precipitation-hardened stainless. 50% stronger than 316, with excellent seawater corrosion resistance. Expensive but worth it on commercial vessels and premium pleasure boats.

    316 Stainless

    The industry workhorse. Good corrosion resistance, moderate strength. Watch for crevice corrosion under cutless bearings and inside the shaft taper. Great value in the 25–50mm range.

    Manganese bronze

    Traditional sailboat material. Soft but immune to seawater corrosion. Easy to repair-weld. Softer than stainless so wears cutless bearings faster — a trade some sailors accept for the longer-term corrosion story.

    Nickel-aluminium bronze

    Harder and stronger than manganese bronze. Suits high-torque commercial applications. More expensive but longer-lasting under heavy duty.

    Decision matrix

    Pleasure boat, moderate budget: 316 stainless. Pleasure boat, premium: Aquamet 22. Commercial workboat: Aquamet 22. Classic sailboat or traditional restoration: manganese bronze.

    A note on galvanic compatibility

    Mixing dissimilar metals in a seawater drive train is a battery waiting to corrode something. Keep shaft, propeller, cutless bearing, and bronze fittings on a sensible galvanic series — and bond and anode everything properly.

    Need advice on your boat’s stern gear or propeller? Call Brian directly on 0413 771 090 or use the contact form — we respond the same day.

    Read Next

    More from our workshop

    Diagnosing Boat Vibration Problems
    Troubleshooting

    Diagnosing Boat Vibration Problems

    If the boat vibrates at a specific RPM, there’s a reason — and it’s usually fixable. Here’s where to start.

    How Your Propeller Affects Fuel Burn
    Theory

    How Your Propeller Affects Fuel Burn

    If your boat is wearing the wrong propeller, you’re burning diesel for no return. Here’s how to see it in numbers.

  • Cutless Bearings — Maintenance and Replacement

    Maintenance

    Cutless Bearings — Maintenance and Replacement

    August 2026 · 6 min read · By Brian Rogers Marine Engineering

    Cutless Bearings — Maintenance and Replacement

    The humble cutless is the most important part most owners never think about — until it fails.

    What a cutless bearing does

    A cutless marine bearing is a bronze or composite shell lined with grooved nitrile rubber. Water flowing through the grooves lubricates the shaft and carries away heat. Simple, reliable, and good for 5–10 years in most pleasure boats.

    Why they fail

    Three main reasons:

    1. Blocked water flow — barnacles in the strut or stern tube.
    2. Dry running — common when a boat is dry-sailed and started before the sea water reaches the shaft.
    3. Shaft misalignment — the bearing wears unevenly and oval-locks.

    The wear check

    Grab the shaft near the bearing and lift. If the shaft rises more than 1.5mm, the bearing is at or beyond its wear limit. Replace before next season.

    Clearances when fitting a new bearing

    Standard shaft-to-bearing clearance is 0.004–0.006″ per inch of shaft diameter. Too tight and the bearing runs hot; too loose and the shaft whips.

    Duramax vs. Tufnol — the long-running debate

    Duramax rubber is the modern standard — tolerates small particulate, runs cool, lasts well. Tufnol (phenolic) is traditional, slightly more tolerant of brief dry-running, but less tolerant of grit. For most boats, Duramax wins.

    Fitting

    Press-fit with a mandrel; don’t hammer. Note the bearing orientation — grooves must align with water flow. We supply bearings with clear install sheets.

    Need advice on your boat’s stern gear or propeller? Call Brian directly on 0413 771 090 or use the contact form — we respond the same day.

    Read Next

    More from our workshop

    Anode Selection for Marine Vessels
    Theory

    Anode Selection for Marine Vessels

    Choose the wrong anode and your prop and shaft pay for it. Zinc, aluminium or magnesium — here’s how to decide.

  • Anode Selection for Marine Vessels

    Theory

    Anode Selection for Marine Vessels

    August 2026 · 6 min read · By Brian Rogers Marine Engineering

    Anode Selection for Marine Vessels

    Choose the wrong anode and your prop and shaft pay for it. Zinc, aluminium or magnesium — here’s how to decide.

    What an anode does

    A sacrificial anode is a block of less-noble metal electrically bonded to the vessel’s underwater metalwork. In seawater, the anode corrodes preferentially — being consumed to protect the shaft, propeller, rudder and engine.

    Zinc — the saltwater standard

    Pure zinc anodes are the historical standard for seawater. They work. The downside is that they stop working in brackish or fresh water (the oxide layer insulates them). If your vessel moves between saltwater and freshwater, think about aluminium.

    Aluminium — the modern all-rounder

    Modern aluminium alloy anodes (containing indium) work in salt, brackish and fresh water. They last roughly 50% longer than zinc on an equivalent-mass basis. The main caution: don’t use aluminium anodes in a diesel engine’s heat exchanger unless the manufacturer approves it.

    Magnesium — freshwater only

    Magnesium anodes are strongly electronegative — too strong for seawater (they’ll alkaline-corrode aluminium hulls). Use them only in freshwater: lakes, rivers.

    Sizing and placement

    Shaft: one anode within 100mm of a bearing. Rudder: one on the trailing edge or stock. Hull: one or two bolted to a dedicated plate. Engine: one in the raw-water circuit. Replace at 50% consumption.

    Checking they work

    Half-cell reference voltage: for a steel/aluminium hull in seawater, read −800 to −1050 mV vs. silver/silver-chloride. For a GRP hull with bronze gear: −550 to −650 mV. More negative, over-protected (hydrogen on bronze alloy). Less negative, under-protected.

    Need advice on your boat’s stern gear or propeller? Call Brian directly on 0413 771 090 or use the contact form — we respond the same day.

    Read Next

    More from our workshop

  • Hydraulic Steering Tips & Troubleshooting

    Troubleshooting

    Hydraulic Steering Tips & Troubleshooting

    August 2026 · 6 min read · By Brian Rogers Marine Engineering

    Hydraulic Steering Tips & Troubleshooting

    A soft helm, a leaky ram, air in the lines — three common hydraulic steering problems and the fixes.

    The three big complaints

    Boat owners come to us with hydraulic-steering complaints in three flavours: soft helm (requires many turns), hard helm (physically stiff), and wander (rudder drifts off). Each has its own fix.

    Soft helm — the air problem

    Soft helm usually means air in the lines. Bleed from the lowest point on each ram port, pumping the helm from stop to stop until fluid runs clear. Top up the reservoir frequently during bleed — pulling the reservoir below the pickup lets more air in.

    Hard helm — the friction problem

    Hard helm is friction somewhere mechanical: a seized rudder bearing, a tight tiller arm key, or a stuck steering ram. Disconnect the ram and move the tiller by hand. If it’s heavy by hand, the fault’s in the rudder gear, not the hydraulics.

    Wander — the leak problem

    Rudder that drifts off centre under boat loads = internal leak in the helm pump or ram. Shut both ram-port valves (if fitted) and see if the rudder still drifts. Doesn’t drift? Internal helm leak. Drifts anyway? Internal ram leak.

    Routine fluid

    Hydrive and most marine systems take ATF (automatic transmission fluid) or specific hydraulic oil per the manual. Don’t mix. Change at manufacturer intervals.

    Hose routing — the long-term killer

    Avoid sharp bends, hot spots and chafe points. UV kills hose covers. A 10-year-old hose in bright engine-room light is a time bomb; replace proactively.

    Need advice on your boat’s stern gear or propeller? Call Brian directly on 0413 771 090 or use the contact form — we respond the same day.

    Read Next

    More from our workshop

    Propeller Slip Theory Explained
    Theory

    Propeller Slip Theory Explained

    Slip is the single most misunderstood number in propeller selection. Here’s what it really means — and why 30% slip isn’t a problem for a trawler.

    Anode Selection for Marine Vessels
    Theory

    Anode Selection for Marine Vessels

    Choose the wrong anode and your prop and shaft pay for it. Zinc, aluminium or magnesium — here’s how to decide.

  • Three, Four or Five Blades — Which Propeller is Right?

    Guide

    Three, Four or Five Blades — Which Propeller is Right?

    July 2026 · 5 min read · By Brian Rogers Marine Engineering

    Three, Four or Five Blades — Which Propeller is Right?

    Add a blade and you add thrust and smoothness — but lose a half-knot. Here’s the real trade-off.

    The simple rule

    Fewer blades = more efficient (higher top end). More blades = smoother, more thrust at a given diameter. That’s the whole trade-off, and the right answer depends on what you want your boat to do.

    Three blades

    Classic planing and semi-planing choice. Best fuel economy at WOT. Simplest and cheapest to repair. Can be rougher at idle, more cavitation-prone when heavily loaded. Good for sports fishers, runabouts, light cruisers.

    Four blades

    Smoother at low RPM. More thrust per diameter — useful when the hull aperture is restrictive. Slight loss of top-end efficiency. Good for cruisers, displacement sail under power, and semi-displacement workboats.

    Five blades

    Maximum thrust, smoothest running. Common on large commercial vessels, trawlers, and premium motor-yachts where quietness is prized. Most expensive to make and repair.

    Workshop lore

    If you can run 3 blades and still make rated RPM at WOT, do it. If you can’t — hull aperture too tight, too much vibration — add a blade. If still not enough thrust, go to five. Rarely do we recommend starting at five without a reason.

    Need advice on your boat’s stern gear or propeller? Call Brian directly on 0413 771 090 or use the contact form — we respond the same day.

    Read Next

    More from our workshop

    How Your Propeller Affects Fuel Burn
    Theory

    How Your Propeller Affects Fuel Burn

    If your boat is wearing the wrong propeller, you’re burning diesel for no return. Here’s how to see it in numbers.

  • Marine Shaft Alignment Done Right

    How-to

    Marine Shaft Alignment Done Right

    July 2026 · 7 min read · By Brian Rogers Marine Engineering

    Marine Shaft Alignment Done Right

    0.05mm around the coupling flange is a job well done. Here’s how to get there.

    Why it matters

    A misaligned shaft turns a smooth drive train into a resonant one. Bearings wear fast, seals leak, hoses chafe, and the whole thing loses efficiency. Spending an hour aligning on the slip saves days later.

    The feeler-gauge method

    With engine mounts loose and the shaft coupled, measure the gap at the coupling flange at 12, 3, 6 and 9 o’clock. All four readings should be within 0.05 mm of each other on a 150 mm coupling. Shim the engine mounts to bring them in line.

    Laser alignment

    For bigger engines or precision work, a laser alignment tool reads angular and parallel offset to 0.01 mm. Overkill on a 20 ft runabout; essential on a 50 ft commercial.

    Cold vs warm alignment

    Engines expand as they warm up. Alignment should be measured warm (after running for 30 minutes) and shimmed to zero at that temperature. Cold alignment of 0.02 mm "high at the front" is a reasonable rule for diesels.

    Flexible couplings

    A good flexible coupling (Poly Flex, R&D) allows 0.5–1° of misalignment and 2–3 mm of parallel offset. It does not substitute for a properly-aligned shaft; it absorbs movement after alignment is done.

    Common mistakes

    • Aligning in the water with the boat flexed on blocks.
    • Ignoring the gearbox hanging flex.
    • Tightening coupling bolts before shimming is complete.

    Need advice on your boat’s stern gear or propeller? Call Brian directly on 0413 771 090 or use the contact form — we respond the same day.

    Read Next

    More from our workshop

  • How Your Propeller Affects Fuel Burn

    Theory

    How Your Propeller Affects Fuel Burn

    June 2026 · 6 min read · By Brian Rogers Marine Engineering

    How Your Propeller Affects Fuel Burn

    If your boat is wearing the wrong propeller, you’re burning diesel for no return. Here’s how to see it in numbers.

    Why fuel burn depends on propeller

    Fuel burn depends on two things in the drive train: how much power the engine makes, and how efficiently that power is converted to thrust. The propeller is the second half of that equation — and small changes in propeller design produce measurable fuel differences.

    Over-propped boats cost fuel

    An over-propped engine can’t reach rated RPM and labours at every throttle setting. Specific fuel consumption (grams per kWh) is 10–20% worse than at rated RPM. Correct the propeller and the fuel savings pay for the work in a season of hard use.

    Under-propped boats cost fuel too

    Under-propped engines over-rev. Mechanical friction losses increase with the square of RPM; cooling fan draw increases; the engine never develops its best torque. Fuel per nautical mile climbs.

    Blade area and cavitation

    Too little blade area = cavitation (micro-boiling on the blade back). Cavitating propellers are inefficient and noisy. Adding blade area — or going to one more blade — cures the cavitation and the fuel bill.

    Real-world example

    A 42 ft prawn trawler we re-propped: original 3-blade 36×26 cavitated at tow. New 4-blade 38×22 with higher BAR eliminated the cavitation. Fuel burn at tow dropped from 25 L/h to 22 L/h — 12% saving on an 8 hr tow night, every night. Pays for the new propeller in a quarter.

    What to check

    • At WOT, does your engine reach rated RPM? If not, under-propped.
    • At WOT, does the engine over-rev? Over-propped.
    • At cruise, does the boat vibrate or sound "cavitationy"? Blade area too small.

    Need advice on your boat’s stern gear or propeller? Call Brian directly on 0413 771 090 or use the contact form — we respond the same day.

    Read Next

    More from our workshop