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It's been a while since this corrosion thead was started so I'll provide a follow up.  As I figured that a powder coat job would be very expensive, I removed all the equipment from the boom then went to town with scotch brite pads in a pneumatic drill, cleaning the corrosion areas down to bare metal.  Then I bead blasted the pitted areas as the pad can only go so far.  After a clean water washdown, I treated the areas with an alodine solution.  After that, several coats of Krylon gray primer was sprayed on then the complete boom was sprayed with Krylon white.  Reinstalled the boom and everything is copacetic.   

Prop attach hardware is available from McMaster-Carr which will fit the stainless steel prop shaft.  The hardware is zinc coated stainless steel.
3/4 - 10 slotted nut 95030A260
3/4 - 10 flat nut 93839A837
key 1/4" sq. 24" length (cut to length needed) 89075K522

Catalina Direct has them.  http://www.catalinadirect.com/index.cfm?fuseaction=product.display&Product_ID=1625

It's the same stuff except that the transducer paint is safe for plastics.  I coated my propshaft and prop with it, we'll see how it works.

I like this one:
(It ain't mine!  )

No, that stuff is for aluminum.  As me how I know.

Thanks Stu.  I bought a can of the transducer paint - seems that WM will only order the other stuff special.  I sprayed on two coats and will apply the third when the prop is mounted.  I loved the picture of the hauled boat, It looks like a small version of the Flying Dutchman from Prirates of the Caribbean.

I removed my prop (15 x 10 three blader) to clean and apply a fresh coating.  I used a scotch brite pad to remove the old paint and see that someone in the dim and distant past used a very coarse grade os sandpaper that cut into the coating.  In the process of cleaning, I see that the prop is bronze with a copper coating?  I want to get it all down to clean metal to apply a fresh coat of protection. 

I found a product from Petit, a zinc coat barnacle barrier 1792, which is a modified epoxy.  It is available in a spray can which contains 93% zinc.  Petit suggests that at least three light coats be applied to protect any underwater metal except aluminum.  http://www.petitprod.com/catalog_browse.asp?ictNbr=120

Make sure you use a stainless cotter pin.  Anything else will corrode away. 

http://www.msc-stainless-fasteners.com/materialsearch/mscproducts/specificproducts/cotterpins.html

I use Visio for all my work drawings, it's part of the Microsoft Office program and it's very easy to use.  Files can be opened on any computer that has Visio installed.  You create a background in several sizes with all your drawing block information then create a foreground overlay drawing size according to the circuit you want to do. 

Thanks guys, all of your responses have been very informative.  We wanted to look at chartering as a way to offset expenses as we don't get the boat out as often as we would like to do.  I have to talk with the charter outfit but from what I have heard, they have a good reputation and are responsible operators.  As Craig mentioned, we have to keep a close eye on it.  We don't expect it to become a business, we want to try to offset some of the cost.

Have you as an owner ever offered your boat to a charter company?  I'd like to know your experiences both good and bad.  We are considering the idea to see if there is a benefit as we don't get on the boat as often as we like. 

That's what I'm going to check.  Media blasting with micro glass beads costs @ $75/hr. then there's the alodine treatment, prime and paint.  I want to compare that to powder coating to see which method will be more effective for the cost.  Watch this space for further updates.

The company I'm considering for refinishing the boom also does power coating.  Anyone have experience with that?  My only concern is to not get the material thickness too heavy as there are clearances to maintain.

I removed the boom from Whisper to take care of the numerous corrosion spots.  I was going to grind it away, then treat the area with alodine, primer and paint but there are so many spots, I decided to have it professionally stripped, treated and repainted.  As for the interior of the boom, I'm going to apply a treatment of ACF-50, a anti corrosion compound used in aircraft maintenance.  http://www.corrosion-control.com/acf50.html.  It's also available from Aircraft Spruce and Specialty.  http://www.aircraftspruce.com/catalog/appages/acf50.php