Hello all.
As ABUFLETCHER says, making your own static props is relatively easy, I have been making my own for a while. I decided to have a go at making a working one, for a Fokker EV, which, as ABU says is quite a daunting thought but as it was a laminated jobbie, using mohogany and lime, it was easy to get the two blades the same, as it has built in contours to follow. I wanted scale diameter but couldn't get scale pitch as the Zenoah 26 would never have turned it. I settled on a 24" x 4" pitch. As it turned out, the model is a bit too keen to nose over, so I don't fly it with my homemade one anyway! The motor turned the prop at about 6500 rpm, loads less than it does on an 18" x 6", and the motor needed some needle adjustment to run throughout the range, but it worked well enough, but as said earlier, I reverted back to a readily available commercial size due to the choice of subject, and its desire to break props if you are not careful. Haven't broke one since though, it's just tempting me to put the labour intensive one back on !!
I also made one for my DH2 which is 30" x 10" scale in outline and diameter, but again cheats in pitch. The pitch wasn't enough so I had another made by Eat Props here in the UK. He cut the blank and rough shaped it, then I finished the shaping, stained and varnished it. He is a very nice man, he ships overseas, just tell him what size and give him a template for the blade shape you require, he'll do the rest. Very good value too!
Hope this helps, Ian.