I think foam/epoxy glassed blades would work fine for a small vawt.You can cut your desired profile out of a 1x4 or whatever and epoxy that to each end that will be your form to follow has well has end supports for mounting.

 Plan on doing this for a rooftop turbine.

 I built a foamcutter basically for free from the great help here.

 Material list;
 scrap pvc pipe
 scrap emt
 element from a junk milkhouse heater(with insulators streched out to~4FT
 transformer from a junk pool robot
 spring from a junk dishwasher

 Worked fine with practice