ORIGINAL: KC36330
the way i cut mine was simply cut them about 1/8" long on both blades, then insert a dowel the correct distance away from my oscillating drum sander and spin the prop into the sander, it'll curve the tips and trim it to the desired size, toss it on a balancer and that was it, nothing more had to be done.
Got to say, having a hard time imagining the process. Can you explain further or maybe show some pictures?