We receive detailed measurements from the engineer and add machining, shrinkage and contraction allowance. We then create a full sized layout of the pattern we can reference while making. We make sections and measurements at intervals. In the layout, we create slices called cants. This is the preparation of the cants. A hole is made in the center of the hub. This is a critical reference point used to take all measurements. The foundry will also use this hole to set up the pattern for casting. The cants are glued together pivoting around the center of the hub. The offset is determined by the pitch of the blade.
The steps are then taken down to create a smooth blade face. The forward and aft sections of the hub being prepared. The foreward end is secured after ensuring it is perfectly perpendicular to the hole in the hub. This face of the hub can now be used as a reference point. Holes are drilled as reference points for measurements. This shows the finished blade face. It is measured constantly while shaping. We add dowels cut to length to reference blade thickness at certain points.
Material is removed from the back of the blade using the dowels as a reference for thickness. The aft end of the hub is added. Filling in the hub. The hub is made to its final shape. In this case, the hub is barrel shaped. Shaping the root of the blade. Using body filler to create the fillet between the blade and the hub.