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I have collected all the materials I required for the next blade making attempt, hoping for it to be the final one that nails it. Just honing my hocus pokus skills aka the making process, at the moment.

Exactly, And it is a little bulky too.

I didn't want to distract the thread but here is the link. https://www.flynow-aviation.com/

This guy uses the front door to abandon ship in case of an emergency. Expensive stuff, nothing like pocket money.

I have spent a long time trying to make ribs and put spars and skin on them but ironically my new method employs no ribs at all. Making ribs was like wrestling in a mudpit which many times I wanted to give up halfway through the hour long process. However the skin fabric that I had bought was...

I will still go with fiberglass composite but employ a different way of construction. There will probably be some need to protect the leading edge but I will not address this issue just yet, I wonder if it can be done by gluing some tough metal on. I may also have some trouble getting the...

I am thinking of a whole new way of making the blades; a method which is more robust in every way and easier to implement too. I will need different tools for it though. If I have some luck in this new method the time I've spent fruitlessly can be compensated.

I have spent weeks ordering products to use in making the ribs and waiting on delivery of them. Turned out that most of the materials I have ordered were useless. I had ordered strips of aluminium to use as templates and tapes and all but there were no ways to shape them precisely. But I have...

The second specimen from the first attempt. The resin got thicker and and an unplanned natural pattern came about. Imprecise and not repeatable.

I have already discovered two ways of how not to make a wing rib. Main issues were; I started using the resin too early while it was still too thin, I need to wait until it becomes a little viscous before I start applying it otherwise the cloth does not stay in place. The more pressing issue is...

After 40 minutes of wrestling in the mudpit I set the fiberglass resin composite blade rib specimen aside to cure. I spent several days getting some stuff out of my way before I start getting may hands dirty with composites. The materials I had ordered had arrived already. The templates I had...

I have actually required this method for my work. You can simply make the ring large enough so that you will have more than enough room for regular moves and you don't need to hit the ring but you can keep a distance to the ring by hand.

I would make a ring positioned around the stick and allow the stick to only move inside the ring. I would rest my hand on the ring and use my fingers.

Making the mold is more of a future thing for me as I will try a mold-less method first. I want to do a wet layup with no vacuuming. As I will make a thin skin I believe issues with wetting the cloth will be minimal. Of course I do not want to use more resin than necessary either. I will not...

@btd1982 does the hocus pocus thing but I guess it won't work here. I will try a mold-less way of doing it. It may be primitive by industry standards but I am hoping it will be quality enough to go through the initial cycle of development. I only need it to hold its form and stand the forces...

Does anybody know how to turn these materials into man carrying helicopter blades?

I dont see how the bolts will go out of alignment with the plates. I am thinking of not twisting the plates but putting a shim that has an angled cut for the blade. So the blade root will mate with the cut perfectly. I also need to cut the plate bolt holes at an angle to match the bolt angle. I...

How about something like this one? My own design that won 19th place at Teknofest Istanbul in 2020.

Four wheel vehicles require crash-worthiness.

The steel hub: This one is meant to be easiest to make, if it does really work. I will upgrade it to a better one when the whole thing works. The sketch does not show but the steel plates are meant to be bent to 7.5° angle at the tips. The blade roots will be made thicker to mate with the...