Superior Props are engineered to save you time—most of the excess wood is already cut away, a true pitch is cut into the back (working face), and the blades taper evenly from a thick hub to a thin tip.
Follow these steps to customize, reinforce, shape, and seal your prop for maximum strength and flight performance.
Required Tools & Materials
Propeller Blank: Superior Props balsa blank.
Reinforcement: 1/64″ plywood sheet (Provided with your Superior Props Propeller Blank purchase)
Items not provided
Small plywood hub washers.
Bushing Material: 3/32″ OD aluminum tubing and 1/16″ OD thin-walled brass tubing.
Cutting Tools: Sharp X-Acto knife or razor, balsa stripper (optional).
Drill Bits: 1/16″ and 3/32″ drill bits.
Adhesives: Medium CA glue, Thin CA glue.
Abrasives: Sanding sticks/boards (coarse, medium, and fine grit).
Before You Begin
CRITICAL: Always identify the TOP or LEADING-EDGE markings on your blank. We write Density, Diameter & Pitch on this edge.
The blade faces you see when looking down on these markings are the back side of the propeller blade—this is the surface you will carve and sand.
The opposite faces (working faces) have been cut to true pitch. Do not carve or aggressively sand the working faces, or you will alter the pitch of the prop. Only lightly finish-sand those faces to clean up the surface.
Step-by-Step Finishing Process
Step 1: Lay Out the Blade Shape
Align your chosen blade template onto the blank.
Carefully trace the outline onto the balsa using a pencil.
Step 2: Reinforce the Hub (Plywood Spine)
To strengthen the hub and prevent splitting, insert a plywood spine prior to shaping.
Mark the Slot: Locate the hub center (front-to-back), then draw a line approximately 2″ long and 1/4″ up from the prop base on both sides.
Cut the Slot: Using a balsa stripper or a sharp X-Acto knife, cut a slot all the way through the hub along this line, keeping it parallel to the base.
Prepare the Spine: Cut a piece of 1/64″ plywood to matching length (approx. 2″) and slightly wider than the blade depth (approx. 1/2″).
Test Fit: Gently test-fit the plywood into the slot until it slides smoothly end-to-end and fore-and-aft.
Glue: Pull the spine out slightly, apply medium CA to the top and bottom of the plywood, and slide it back in. Wipe away excess CA. Run a drop of thin CA along the glue joint on the opposite side to fully wick into the balsa.
Trim & Flush-Sand: Trim away the protruding plywood with a sharp knife and sand it flush with the surface of the blank using a sanding stick.
Step 3: Cut & Sand the Blade Profile
Rough Cut: Using a sharp knife, carefully carve away the excess balsa near your pencil line, keeping the blade perpendicular to the surface. Leave about 1/16″ to 1/32″ of material around the line.
Sand to Line: Use a sanding stick or board (perpendicular to the blade surface) to sand down precisely to the pencil line. Use up-and-down strokes to rough in the shape, followed by smooth side-to-side strokes.
Step 4: Carve & Sand Blade Contours
Bevel Edges: Working only on the back side of the blade, use a sharp knife to bevel the edges by cutting across the grain to prevent splitting.
Thin the Tips: Gently thin out the blade tips with your knife.
Smooth Sanding: Use a sanding board to bring the back side of the blades down to your desired profile and thickness. Finish by lightly sanding the working face just enough to smooth the wood without altering the pitch.
Step 5: Seal & Finish the Wood
Apply a couple of beads of thin CA to one blade surface and spread it evenly across the balsa.
Allow it to set, then sand smooth with a fine sanding stick.
Apply a second, lighter coat of thin CA and finish-sand with a fine-grit abrasive.
This creates a hard, durable satin finish that protects the balsa while adding minimal weight.
Step 6: Install the Hub Bushing & Washers
Drill Guide Hole: Insert a length of 3/32″ OD aluminum tubing into the factory center hole as a drill guide.
Drill Plywood: Carefully drill through the newly inserted plywood spine using a 1/16″ drill bit by hand. Follow up with a 3/32″ drill bit to match the original hole size.
Attach Washer Reinforcements: Glue small plywood washers to both the front and rear faces of the prop hub using medium CA. (Keep extra tubing inside the hole while gluing to ensure alignment).
Install Outer Bushing: Cut a piece of 3/32″ OD aluminum tubing so it leaves about 1/32″ excess on each side of the ply washers. Coat with medium CA, press into place, and secure the joints with a drop of thin CA.
Flush-File Bushing: File or sand the protruding aluminum tubing flush with the plywood washers.
Inner Bushing: Slide a 1/16″ OD thin-walled brass tube (cut slightly longer than the aluminum tube) inside to fit your prop shaft wire.