Hi,
Well, a question like that one is pure catnip to me!
Here's the story of my blades, with notes about the WT's they were on, but none of the technical details. I don't think you need dimensions and specs so I'll stick to the experience selecting, carving, protecting, and durability.
I will also ignore many experimental carvings where I was just learning technique and trying new tools. All blade sets in this list actually flew on a WT.
Blade Set #1, 2007
Designed per Hugh Piggott spreadsheet, however I made adjustments of my own. Actually had excessive twist. Started up great, limited by stall (but I didn't know that at the time).
Fabricated with laminated cedar. The laminations went flat-wise, so the tip was was just one layer of cedar. The root was 6 layers thick.
Durability was limited because I treated them with linseed oil rather than a hard varnish. I also didn't have the leading-edge tape on for the first 4 months. The tips were all chewed up so the tape was too little too late.
The generator in that WT started out as an axial flux. It burned out in 4 months. I replaced it with my first motor-conversion.
This set of blades was destroyed in an accident lowering the tower. One survived well enough to be a template for the next set (except... read on...). I tried to study their performance by building an electronic datalogger, but it didn't work and I couldn't learn anything.
Blade Set #2, 2009
Designed per Hugh Piggott spreadsheet. This time I knew more of what I was doing, and I had written some analysis of my own to learn more. This is where I found my twist error. My work gave me a way to input different airfoil profile parameters, and I learned a lot about what matters and what doesn't. For everyone's sake, sticking with Hugh's spreadsheet almost can't be beat. My adjustments addressed the tips better and I was delighted how quiet they were. My analysis also accounts for the power curve of the generator. If the genny lets the blades run fast (too small) or loads them down too much (too big) I was able to see that. Approximately.
Fabricated with laminated cedar. The laminations went flat-wise, so the tip was was just one layer of cedar. The root was 6 layers thick. So far these were pretty much the same so that I could re-use the same hub. This time, while I was carving, I noticed the different hardness of the epoxy I used to bond the laminations and the cedar itself. I had noticed a "ridge" pattern on th eprevious blades due to this. Unfortunately I was committed at that point. From this lesson I didn't want to laminate flat-wise again, they should be laminated edge-wise.
Durability was much better because I protected them with a hard varnish and added the leading-edge tape. Seriously pitted by a hailstorm in 2016 but they were intact enough to keep running. The next year splits in the cedar started. The splits followed the wood grain along the trailing edge.
I built another motor-conversion because I was so impressed by the first one. This one was well de-cogged, ran quietly, and didn't self-limit. Later, I built a datalogger that did work, and I was able to study performance in detail. This blade+generator combination had great performance in strong winds but didn't start up in low winds, missing out on a lot of energy. It wasn't just because they were worn out; I knew I needed bigger blades. These blades lasted almost 10 years before I replaced them.
Blade Set #3, 2019
Designed with my own analysis, but cross-checked with Hugh's spreadsheet to be sure. Spent extra time using the data I had logged to make them match the generator's power curve. Risk was that the bigger blades would run too fast (more power collected) causing more noise, more wear, and the tail to fold excessively often.
Fabricated with laminated cedar (it's an addiction now). The laminations went edge-wise, so the tip has several pieces of cedar. The root was 12 pieces thick.
Durability improved again due to their size and arrangement of laminations that should reduce tendency to split. Same varnish. Leading-edge tape applied liberally - not just on the leading edge but across the chord. These blades were also struck by two severe hailstorms (not as bad as 2016 though) and emerged completely unscathed. What did "scathe" them was a bad job I did with Loctite in the hub, which allowed them to "unscrew" and come flying off in 2021. They departed as a unit, skidded down the guy-wire, and cartwheeled across the field, knocking down an electric fence. Despite the drama, it didn't take much work to repair them. Even the tips were OK. Some days I do well because I'm smart, but more often I'm just lucky. These are still going today, and they are still very quiet. I replaced the generator in 2022, which unfortunately is noisier because I didn't de-cog it properly.
Since that account was focused on building and using the blades, I've skipped a lot of other things, such as sizing them properly.
A couple of months ago, another member asked about durability of various WT blade materials, and if you can find the reply I gave, that might also be helpful.