No direct experience with anybody who has self-made a composite prop. The prop is, in my opinion, one of the most critical components on an aircraft and has to endure an obscene amount of abuse, so I leave that stuff to the professionals! Now, all that being said, it would be a neat project to try one out!Has anyone tried to make a composite propeller with a closed cell foam core? Any idea how the hubs are made in conventional composite propellers?
Here's a discussion. No indication this fellow actually built one but his idea sounded good. The site has changed but it's in the Wayback machineHas anyone tried to make a composite propeller with a closed cell foam core? Any idea how the hubs are made in conventional composite propellers?
Might be an idea to machine it in two parts.The GA props tend to be wood core covered. Probably for the hub attachment ease. The big composite props i have been around have a foam cores but they are dense. I believe they must have mold halves and partial cure them, lock them together and fill with the foam. At what point they cure the whole thing is a guess, but the foam might have heat cure too. Its closer to a hard plastic. Hub attachment inserts would need to be planned out in the construction phase.