Some of the special wood used for the propellers. It includes sapele mahogany, American Ash and European Beech and black walnut

Wood stacked up, ready to be used

One of the many propeller templates Jeff uses - this is part of a design for a 4-bladed prop

Tiger Moth propeller template

Two cardboard templates shaped like propeller blades with markings and measurements, placed on a concrete floor. Left one is for a Sopwith Pup, the one on the right is for a Gypsy Moth

If you look close enough you can see the see-through plastic laminate template that Jeff uses to trace the shape onto the board ready for machining/cutting (Tiger Moth prop). Finding the wood grain's centre line

A Tiger Moth propeller sits in pieces waiting to be glued up. Also note the "test block" in the clamps - this is to test glue integrity

Laminations for 2 x BE2 propellers. Sapele mahogany wood

Stack of wooden chair backs with drilled holes, markings on surface, and date imprint "17/11/2005" in yellow.

Laminates for a Sopwith Scout

The start of the gluing process of a Tiger Moth propeller. See the full video of this on our YouTube channel

Gluing the Tiger Moth propeller

Placing glued boards into the press bed

Making sure each glued board sits properly in the press bed

Adding the final board on top before getting clamped in the press bed

Glued, clamped in, now in press bed under 5-10lbs of pressure for around 2 days (Tiger Moth prop)

Showing the hub section of the prop in press bed (it looks like a nice cake!)

This is what the tip of the blades look like once glued and inn press bed

This was a demonstration of the unglued boards being fanned out in place on the press bed

Another angle of the demo

Each board is held exactly in place thanks to the wooden braces

Another view of the demo of how it looks before being glued and stuck back in this press bed

The bolts and brackets which clamp down on a glued propeller all have to be clamped down to the exact same level to ensure a consistent clamp all up and down the prop