*Most pictures should be clickable* Since I carved my first prop with the wrong direction of rotate and I didn't want to spend another $25 on wood and the time carving another 4 blade prop I decided to try making a 2 blade foam prop. (thanks for your help Jerry)

I had to glue a piece of 2" and a piece of 1" together to get the correct thickness, then I dado'd out the center for a piece of 1/4" plywood, I did this because I though if I tried to drill the holes in the hub through foam the drill bit would wonder and put the holes in the wrong places. Next I'll drill the center hole and drill the four holes for to mount the hub. But those four holes will be 1" dia. so I can glue a dowl rod in them so when I tighten down the hub bolts I won't smash the foam.

Here is the leading edge template

The trailing edge template

I didn't have a hot wire set up so I just used a hacksaw blade and cut acrossed the templates. It actually worked pretty good.

Here is the prop all sanded and ready to be glassed. I forgo to take pictures of it while I glassed it, but I put 3 layers of 6 oz glass on the entire prop, 4 layers on the inner 2/3 of the prop and 5 layers on the inner 1/3 of the prop. It came out really strong and light. Go back to my main RC hovercraft page.