Complete refurbishment to zero time if you send it here:
http://www.mt-propellerusa.com

Although, there are other MT authorized shops closer. There is a good one in Tuscon, even so you can probably find a closer one. I just sold a 2 bladed MT, and it first went to MT USA.

Prop overhaul times are optional for part 91 operations. However, it is not always a good idea to go beyond, for reasons of corrosion and so on. Prop overhauls are a combination of inspection and mandatory parts replacement. They also dress metal props and re-paint them. On composite props, they may, depending on their condition get several different processes applied. They have multiple coats of finish on them, in addition to layers of glass and or kevlar with metal mesh. There is also a copper paint layer for conductivity to dissipate static charge. The metal mesh is for lighting strikes. So they usually re-apply these coatings as required. They may replace the leading edge for erosion or de lamination and cracking. Normally, an overhauled prop is almost indistinguishable from a new one. On metal props, they may get thinner in cord as they dress out imperfections, material can only be removed, not added. Composite props end up the same as new ones, as material can be added.

My prop supplier, Sensenich in GA, also is a MT dealer and overhauls them. There are lots of them about. Your A&P/IA may have issues installing as a replacement, a prop beyond overhaul times. Continuing them in service already installed is a different matter.

Jr Cub Builder
After reading your post I had to re-read the TBO for the MT where it concerns my engine. TBO appears to be specific for each engine. The O-360 Lycoming series is listed at 2400 hrs or seven years. The start time definition for the TBO sounds rather ambiguous. It states: "TBO starts with installation on the aircraft, but this must not be more than 24 months after new assembly or overhaul and proper storage. Otherwise the TBO starts with the date of manufacturing."
What the hell could that mean to a Philadelphia lawyer?

I am also interested in what the costs are for overhaul and what is required in that overhaul or inspection as I am ready to order a three blade very soon. In my case it is not make or break to know the answer, I will buy it anyway as it appears to be both the best first and second choice for my kind of use. Knowing the answer just helps in the planning.

Dog Pilot (Late edit)
I thank you for the explanation. I was still writing mine while you posted yours so some of the answers you wrote answered my questions before I asked them. I'm not as stupid as it appears. Stupid yes, just not as much as it appears.

Rob wrote

I just sold a 2 bladed MT, and it first went to MT USA.

Rob, Does that mean you didn't like it or? Just curious.

Prop shelf life is not actually a lawyer thing. It has to do with the rubber parts, seals and such. Some of these things fare better working than sitting. I would much rather buy a plane that had 800 hours in the last 10 years than 80 hours.

Just remember props and their rules are more akin to witchcraft than engineering. Performance and operational utility is very individualized. So a Caravan operator who is a cargo hog from paved strip to paved strip would rave about the McCauley metal prop. I sell them or trade them off as soon as I buy the plane. I want them to last in the field, as I pay for my leased aircraft prop overhauls from reserves. Composite props last, for me at least.

Jr.CubBuilder wrote:Has anyone here had an overhaul on their MT propellor? I've been looking at one, and it evidently needs to be overhauled every 72 months or 1800 hours, but it doesn't say what this entails. Is it just an inspection, or complete refurbishment?

Its my understanding that Northwest Propellers, out of Puyallup, WA, can also overhaul it. They have a great crew in that shop with no BS.

180Marty wrote:Rob wrote

I just sold a 2 bladed MT, and it first went to MT USA.

Rob, Does that mean you didn't like it or? Just curious.

No, quite the opposite. It did exactly what I wanted and that was to keep the big motored CG as close to stock as possible. With that prop this plane's landing characteristics where more cub like than any Cessna I have ever flown....

Unfortunately, for the other 90% of my flying, it just wasn't enough prop. I got the chance to test a 3 blade MT and never looked back. The take off performance of these two props on my O-520 was not even in the same ball park...

They're all compromise

Back to the original post, A zero timed MT will for all intents and purposes be a new prop. Unlike metal props these things do not get shorter, thinner, or lighter with re-build. And chances are very good it will get stripped to the wood core and get new sheath... mine did. If it comes from MT USA, you will not be able to tell it from one that just came from Germany.

Take care, Rob