Armortek

At War and Peace last year I saw a wooden propeller for sale which I really liked, but it was a little too expensive. Surfing the net showed that propellers were expensive so I decided to carve a 1:1 scale one myself.. I found a rough set of plans on the internet as a starter.


First you make a full set of templates out of old wall paper

Then you cut out sections of the blade at various stations

You cut out the sections with a band saw or jig saw

You stick the sections together

and you end up with a big block of wood shaped very roughly like a propeller - this thing is 96 inches tip to tip

Using an angle grinder I cut the aerofoil sections at the various blade stations using the section templates as a guide.

You carve between the sections to get the blade shape. Getting the two blades identical is not easy.

Finally after using a hole saw to cut out the centre bore and a drill for the eight bolt holes followed by lots of sanding, painting and varnishing you end up with a finished propeller.

I added a data plate and genuine prop sticker I got from a museum in New Mexico.


I also bought a Russian MIG 25 cockpit clock to fit in the hub.

Hello Allan
Wow I must say the final thing really looks the part and very well done indeed but ... bloody hell! that looks like one hell of a lot of work you have done well done again,now if you can shave down the time to make one and do say two a week you will have a nice little earner on e bay
Only kidding well done mate I would not have had the staying power for that one.
Cheers Paul

I am deeply impressed!

/Chris

Hi Allan

That is outstanding! Any chance on making an Axial propeller for me that I can stick on my Dr. 1 when I get around to making one.

Happy new year to you and your family
Tim

Thanks guys. It was quite e bit of work but I did most of the carving with a spoke shave - a rather old fashioned wood working tool nowadays. I tried a surform but it created such a rough surface it made finish sanding a nightmare. The prop is made from mahogany which is a very easy wood to work with. I don't kno about making any more but it would be good to copy a geuine WWI prop from, say a Bristol Fighter.

Thanks guys. It was quite e bit of work but I did most of the carving with a spoke shave - a rather old fashioned wood working tool nowadays. I tried a surform but it created such a rough surface it made finish sanding a nightmare. The prop is made from mahogany which is a very easy wood to work with. I don't kno about making any more but it would be good to copy a geuine WWI prop from, say a Bristol Fighter.

Allan,
Really cool project, and excellent result. I like the idea of the clock in the center. I think you have found your second calling - prop carver! You can take some brass or copper sheet and make the protective tips - that would be cool addition to your masterpiece.

Thanks for posting the photos. I always wanted a WW1 Fokker or SE5 prop hanging over my mantle.

Kind regards, Bob

Robert,

Thanks for the kind comments. I did think about addng copper to the tips but I decided against it because I couldn't find detils of how it was done. Also many WWI props were fabric covered which I didn't want to do as it looks a rather rough finish. SE5 or Fokker props are really quite expensive if you can get hold of them. I am now making a wall bracket to mount the prop in the dinning room before the boss changes her mind!!