Yeah, I posted this same information on another thread here, related to Cessna 170s. I got caught as well.
There have been VERY few failures. Hartzell is somewhat infamous for using AD's to retire older props, at least in part, I'm sure to reduce their liability.
As far as the eddy current inspection, forget it. First, you have to remove the prop from your airplane. Whoever designed this thing should have to serve time in purgatory removing and replacing these props. It REALLY sucks, and it takes a while. Shop rate.
Now, you have to ship the prop in to a shop with the requisite equipment. Shipping costs, plus ya gotta have a box for the thing. More $$
The prop shop has to DISSASSEMBLE your prop to do the test. THen they have to reassemble it. My guess is they're going to require the blade butt test to accomplish this. That's an overhaul, every 100 hours.
Big bucks, and MAJOR hassles, not to mention down time.
If I were you, I'd whine and snivel as much as possible to convince them to trade you to the 80 inch prop--it really is a MUCH better prop for these aircraft. But, when you do this--make absolutley certain that you have the CORRECT SPINNER AND BACKING PLATE for the stc. Avcon conversions don't. In that case, you are going to want the WHOLE kit for the long prop--prop, harmonic damper, spinner and backing plate.
MTV