ORIGINAL: TFF
What you need is a go/no go gauge of each station; front and face. If you square the hub first, you can make a jig to hold the prop; cut and compare until each station is close.
I've seen examples of the section templates (one for each station) that prop carvers use to check their progress. But that still doesn't get at how to determine the outline of each flat layer (as seen in the last photo of my post above) of the prop prior to carving.
Short of A LOT of expensive trial and error, I can't figure out how to make a template for each layer.