Decided to make a larger more accurate set of blades to use on a motor conversion I'm working on.
These use the full length of the plastic panels I've got.
Length is 38", root 8", tip 3", hub is 15", plastic is 1/4" thick.
Used a round over bit on the router to make the leading edge and a straight bit to shape the trailing edge to a sharp point.
Attached the trailing edge to the hub with two bolts and used a 4" machine screw to jack out the leading edge to 2 3/4" from the face of the hub.

They track almost perfectly which really surprised me because when I flexed the blades with the jack screw they curved forward about an inch at the tips.
Right now there's no load on them and they spin up nice. They are almost as fast as the shorter 5 blade unit.

Now I need to get the lathe work done on the rotor.
Fishbonz