Make a wooden box slightly larger than the prop.

Use modelling clay to fill the box halfway

Use epoxy resin and fiberglass to make a female mold of the front face of the prop

Front face mold, just removed from the box with the modelling clay still stuck on the back

Front face mold, complete

Insert some wooden pins so that the second half of the mold has something to align to

I pulled a vacuum on the epoxy resin hoping to remove some air bubbles (these cause pin holes)

Both halves of the mold, ready for first use

Cut several pieces of fiberglass cloth (6 oz) the same shape as the prop. Always go the full length

The first few pieces of cloth laid up in the female mold parts. You use smaller and smaller pieces becasue the middle of the prop is thicker

Put both mold halves together and clamp

Just the top mold removed. It is still stuck in the lower mold.

Completely free of the molds

Use a pliers to nibble off the flashing around the edges

Sand Smooth the edges. Finished part weights 10.2 ounces

Installed on the 35% CAP