I used generic cold galvanizing spray for $12/can
I have used Pettit Zinc coat for the past 3 seasons in New England and can attest to it's efficacy at minimizing growth on the prop and shaft. In terms of cost, I still have half the can left.
Most of this stuff is 90+% zinc, so the rest of it can't be doing much, except evaporating. One key is that you need to wet it down for 30-60 seconds after your last coat. Seems to change it somehow.
Tried it for the first time last season. Definitely minimized barnacle growth. The prop and shaft are still well coated (the stuff dries at 90+% pure zinc).
Don, have you ever cleaned back down to the metal to see if it is affecting anything? Might be a public service if you did so. I can do so, but you have been doing this for a longer period of time and have a better data set. I am not suggesting to clean the whole thing, just a small patch on the prop so we can see if it apears to be leaching anything. I will do so too. Barnacles area PITA and there doesn't seem to be a good solution out there other than the $100 two part Interlux product. After reading spotty reviews on that I thought about the cold galvanizing, which I bought to treat some steel backing plates I made for the bow cleats on my old boat. I just thought that, given I was bolting a zinc on their anyway a layer of sacrificial zinc on the whole thing might do some good too. I didn't know Pettit even sold it at the time. I even considered marketing it myself, but decided it would be too much work given the government red tape.