The propeller spinner (nose cone) on my plane had cracked (again), so it was time to do something about it. It's spun aluminum, originally about 6 1/2" diameter. The first time it cracked, I stop drilled the crack and riveted a reinforcing plate inside, with another identical plate on the other side for balance. The second time it cracked, I decided to take a different approach, since I figured it would keep on cracking around the prop blade cutouts.
The spinner was originally sold as a "skull cap" spinner, intended to mount in front of a [larger] prop, without cutouts, but the previous owner had modified it to fit over the prop with the cutouts. Anyway, I figured I'd convert it back to a smaller skull cap.
The first challenge was to cleanly and accurately cut it. This project provided the justification to finally buy a rotary table, so I did (a 6" Accura/Vertex). I first bolted a piece of plywood to the table, routed a circular groove in it, and epoxied the spinner into the groove. I then used an .020 slitting saw (jewler's saw) to cut the spinner in half. As the cut proceeded, I used hot melt glue to hold it in place:
Next, I had to make a new backplate. I don't own a lathe or even a boring bar, so the rotary table would have to serve. I first xy'd the six mounting holes in both the new plate as well as a 1/2" thick tooling plate. With the backplate bolted to the tooling plate and indicated in, I first cut the outer circle, then machined it to the proper diameter with a step to receive the spinner, which I finished with a 60° countersink tool to match the spinner shape.
I then had to rework the center boss to a shorter length (again, no lathe, so I clamped the boss in the vise, indicated it, and drilled and tapped it. Here's what all the pieces looked like when finished:
And finally, what it looks like on a spare prop (I won't get to the airport to mount it on the plane until next week, I need to get a new center screw, too):