Thank-you for all of your replies.
I have talked to Wayne at soloprops, he can supply up to 32" dia. Not quite large enough but I could use one for a template.
Don't want to go the ultralight direction as I am looking for a scale prop but thanks for the reply.
Paul: your work looks absolutely incredible. I would buy that just to hang on the wall. What are you putting that on? I would like to see some pics.
Part of my dilemma is finding drawings of the prop so that I can carve one. I may have to get a smaller one and use it as a reference.

Kevin