OUCH - %$#^&@*(&^#%$ (to quote what you said when you seen it)
It looked repairable to me. Did you find out what caused it??
I've had several "dings" that I filled in with FLOX or JB weld.
Metal Props - Rutan recommended to NOT install a metal prop. Seems that a Metal prop is like a tuning fork. The frequency resonance of a prop/engine combination is part of the testing thats performed for spam can certification, i.e. avoid the resonanat frequencies as these will set up airframe osscilations that could shorten the life/destroy the airframe.
A perfect example of resonant frequancy response is the Highpitch signer shattering a crystal glass The singers voice was able to match the resonant frequency of the glass, AND instill enought power to cause it to shatter.
A wooden prop also has a resonant frequency, BUT, because of the dampaning effect of the wood, its impossible to instill enough energy into the prop to get it to vibrate like the tuning fork.
NOTE - Do you have a spare prop?
Waiter