Props are an important piece of an equipment on your aircraft. It must be manufactured in the utmost precision and craftsmanship. So, proper and accurate jigs must be built first.

Pic. 2. shows the 4-bladed alignment jig/clamp. In the center of this flat board is a threaded hole for a 1/4-20 bolt. On a common radius is 4 dowel alignment pins spaced 90 degrees apart. Use a compass and square to draw lines on this wood or on a piece of paper. The holes must be drilled on a squared up drill press.

Pic. 3. shows the prop/router holder. The height of the 2 sides are flush with the thickness of the prop.

Pic. 4. A high speed router and pic. 1 is the router bit. Look carefully at this bit. I've ruined props because of using different types, shapes, No. of flutes and diameters. This bit is ~3/8" dia. with 2 flutes.