I submitted a bunch of images and instructions to instructables.com and a printable pdf file with instructions is linked here (printable pdf instructions)
First step in fabrication was drawing the templates. To get the proper airfoil shape and blade twist, the CATIA model is sliced into sections and then printed out in a 1:1 scale.
Each station along the length of the blade is measured and a profile slice is made. The drawing to the left depicts the overall dimensions and shape of each airfoil section. I created the drawing using CATIA's drafting workbench.
Just for fun I created some slices through the propeller's longitudinal axis. The dark regions depict the exposed profile of the wood if you took a saw and cut slices along the top and bottom as if it were cheese at the deli.
Next, I measured the thickness at each station so that we could cut the wood into sections.
Then, Mark cut out the boards and glued them together. Note that the thickness varies from the center to the tip. This is to conserve wood, and save time cutting away the unwanted wood (hogging).
Next we print out the 1:1 scale templates and glue them to aluminum sheets so that we can cut them out and use them as profile templates.
Here I am filing down one of the aluminum templates.
Here the profile is cut out and we are ready to begin the fun part. Hand tools.
Mark starts hogging out the hub with hammer and wood chisel
I was nervous at first using the Pneumatic air chisel. But eventually I get the hang of it. And let me just say that it is lots of fun.
Mark gets fed up with slow progress and starts hogging out large chunks wood. I'm nervous in this picture.
After a long day of work, it starts to look like a propeller. But lots of work still to go.
Here I am holding the unfinished propeller.
Mark holding the unfinished propeller.
The next couple of weeks we meet at marks apartment to finish the delicate work of carving with the spoke shaves and draw knives.
Here is a look at the shape un-sanded and still unfinished. It took us about 4 meetings of about 3-4 hours to actually bring the propeller down to shape
Here is the almost finished propeller, still needs a sanding and few coats of varnish.