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How To Build Wooden Propellers

Building a wooden propeller is a great way to combine a passion for aviation with a hobby like wood carving or wood working. It is important to plan the design of your propeller before beginning. Study the design of different propellers before deciding how to maker your own. The steps below are based on a three-bladed propeller. The blades will be constructed separately and when they are assembled, the base of each blade will form the hub of the propeller.

Things You'll Need

Band saw
Safety glasses
Drill press
1x6-inch Pine boards
White glue
Glue brush
Wood clamps
Calipers
Measuring tape
Sandpaper
Hand plane
Draw knife

Instructions

- 1
  Create the plans for your propeller using a computer aided design program, taking care that the dimensions are accurate. You can use another propeller as a model for your design, or you can purchase a design template online.
- 2
  Gather the wood required based on the dimensions of your design. Pine can be used, as long as it is of high grade, without knots.
- 3
  Measure the size of each board compared to the specifications of your design. You will have to stack between five to nine pieces of 2-by-6 boards to account for the angle each blade. To save wood, the boards can be of varying lengths, as long as the propeller can be carved from the stack when they are glued together.
- 4
  Put on the safety glasses and cut the boards to the required length and width with a band saw.
- 5
  Glue the boards together for each blade using white glue and a brush. Apply glue to both sides of the board, spreading it evenly to the edges and corners. Then clamp the boards together, with wood clamps spaced evenly across the length of each stack of wood. Allow the glue to dry overnight before removing the clamps.
- 6
  Draw the outline of each blade on the boards. Where the blade curves, measure the curve at nine different points, evenly spaced, and then connect the dots with an arc.
- 7
  Carve the straight edges of the blades, including the base portion that will form the hub, with a hand plane. Carve the length of the blades with a draw knife, working from the base and carving towards the tip. Use long, even strokes, shaving thin layers of wood. Do not dig too deeply with the draw knife or you will gouge the wood. Use calipers as you work to compare the size and shape of the blades with the design.
- 8
  Assemble the blades on a flat surface. Measure the distance between the propeller tips to make sure they are exact.
- 9
  Apply glue to the edge of each base where they join together using white glue and a brush. Clamp the bases together with wood clamps. Measure the distance between the propeller tips before completely tightening the clamps. Let the glue dry completely before removing the clamps.
- 10
  Drill a straight 3/4-inch hole in the center of the hub so it can later be fitted on a propeller shaft.
- 11
  Sand the blade to a smooth finish, then paint or varnish the propeller as desired.

Aviation