Hi,
I needed a 4.5 inch prop for my new steam powered boat with a 1.5 pitch/diameter ratio, but couldn't locate one from the usual sources - so I decided to make one.
I made the 1 inch hub and filed out the 2.5mm (excuse the mix of measurements!) grooves for the blades, made the blades by superglueing the brass sheet blanks together, split them, weighed them for balance etc.
The problem then arose on how to keep the blades in exactly the right alignment whilst silver soldering them to the hub.
I was going to build a jig to hold them individually, but then had the idea of drilling through from the rear of the hub, threading M3 and inserting a clamping screw for each of the blades.
This idea worked a treat. I could keep adjusting the blade positions until I was satisfied, then took the brave step of silver soldering. After the prop had cooled down, I filed off the screw heads and Roberts your father's brother!
A couple of pics showing the front and rear views.
Ian