The front of the "carving machine" or "copy lathe" - designed and built by Jeff using bits and pieces from around the workshop (even old skateboard wheels)

The "master" propeller goes in the bottom, and the new uncarved freshly glued prop goes in the top

A circular saw slowly cuts the real propeller, held in place by a wheel that runs over the "master" propeller, ensuring it's roughly cut to shape

Another angle of the cutting machine (we have a video of this process on our YouTube channel)

This is the copy-router (another machine Jeff built). Once a prop has been roughly cut in the cutting machine/ copy lathe, it comes to here to get a more refined carve

The tip of a prop that has just come out of the carving machine. Notice how it's still quite rough. That's where the copy-router comes in! Only a 2 bladed prop can go through the copy lathe

A prop fresh out the of the carving machine/ copy lathe, ready to be copy-routed

The prop now being lined up in the copy-router alongside the "master" propeller

Getting screwed into place on the copy-router

This special machine does a much closer and refined carve, running over the original "master" prop and copying that exact measurement of cut onto the real propeller (video of this on our YouTube)