I had time for a little more research and I've got to believe two things:
- The Frank's propeller definitely was a design flaw. The short length and low pitch angles (I'd like to one day get a copy of the diagram, but for now I assume it's correct) guarantee that its horsepower at max boost isn't converted into thrust.
- The Frank's abundant wiring suggest that Nakajima intended on increasing its electrical system's voltage in later production versions.
So first up, let's talk a bit about US electric props and why pitch angle and prop size were important to thrust:
The only electric propeller used by the US military during WW2 was the
Curtiss Electric (which is why the Middleton report compares the Frank's Pe-32 propeller to the Curtiss Electric prop). The Curtiss Electric prop and electric governor were used on a lot of aircraft, including the P-40, P-38, and some versions of the Mustang. The governor was produced under four primary model types: the
100008, the 100001, the 100005, and the 100006. But of these. only the 100008 was common during the war. Yes, if you click on that link, someone is selling a Curtiss Electric 100008 governor, for not that much money.
Getting back to the topic, you can see there's a
direct relationship between prop size, engine horsepower, and pitch limit. When the Allies put a Merlin in a P-40L and increased its pitch limit, they got a maximum speed of 368 MPH. The higher pitch limit allows for the horsepower to be fully utilized at maximum output. However, the big question is how much voltage do you need (VA=W)? The Warhawk had a 24-volt system.
According to Greg, the Frank had a really low voltage system, yet extensive wiring. Greg speculated that they planned on putting more wood in the fighter, which doesn't make sense (wood is resistive and won't conduct electricity). The more likely explanation is that Nakajima planned on upgrading to a higher voltage system and therefore a better pitch angle on the governor because more volts = more push (V=MA). Because the Frank tested by TAIC is from Clark, it was not the final production series.
In all likelihood,
later versions of the Frank were probably capable of better pitch angles. The US (on a bigger, badder aircraft) managed to get the pitch limit to 65-degrees
inches on an electric prop. To illustrate, the 100008-3J pitch governor on the Black Widow P-61C could hit 65-degrees
inches. This was the fastest variant of the Widow, although it was more or less a post-war model that never saw combat during WW2 AFAIK. My guess is that the Japanese were probably able to increase the pitch governor's angle although there's no evidence of that. The only thing we do know is that the Frank that was tested was
manufactured in the Summer of 1944. That's toward the beginning of the Frank's production run. In other words, we know early production aircraft are quite different from late production. But I digress. Getting back to the pitch angle.
You can see that the US also had problems getting higher pitch angles on their electric props. The
published pitch angles for electrics are similar to the angles listed by
taly01 for the Pe-32 although the prop used on the Merlin-powered P-40L reaches a maximum pitch angle of 58. In comparison, I'm positive that the
Hydromatic prop could hit much higher pitch angles. But more or less, it's telling that the US only used electric props on lower horsepower engines. On 2,000 HP and up, they seemed to universally use hydraulic props.
However, I can't locate the pitch limit for the Corsair's or Hellcat's propeller, but I believe it's about 65-inches. If
DarrenW knows, it would be useful for comparison.
As it stands, we do have good evidence to suggest that the Frank's propeller probably gimped its performance.