Interesting. I wouldn't do any machining on the flange as you would have to reset all the diff preload as you would have to remove it to do the job. I would do some very thorough hand scraping to just remove all the rust scale and then a smear of waxoyl to inhibit further corrosion. If you have an old flat file and grind the teeth off and then put a slight radius on the end it will do a good job of the scraping.
Just a thought. Was your special flange fitted before the prop was balanced? It should have been. Did you remove the flange to enlarge the holes and if so did it go back on the yoke in exactly the same position or was it replaced 180 degrees from original? Peter.
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