Kevin,
Dave Platt wrote an article on how to carve a static prop long ago. Don't know if it's available but he describes the process in one of his excellent videos.
You'll need front and side views of the blade scaled to your model. Glue to a balsa block and bandsaw the shape in both planes. The rest is carving to shape
which sounds difficult but in fact is easy and enjoyable. After sealing and sanding the single blade can then be molded in silicone rubber and cast in a quick-setting urethane resin.
Here are a few shots of two I've done (my first attempts). I put it on an aluminum rod to locate the pin when the mold was made.

Best of luck,
Paul