Thanks bryan1, I guess you read post#4 before I edited it. The 48" blades I bought on ebay were about $80 shipped, so that's cheaper than my time would be to carve my own, especially since I've never done it and and am too much of a perfectionist to make them in a reasonable amount of time. Maybe someday if I run out of other projects (not likely.) I'm pretty happy with how much torque and speed at low wind the old PVC pipe shape provides, although I don't have any "real" airfoil blades to compare them to. For now I need to spend my time getting the bigger one built with furling that works, putting up the tower, getting the control panel built with data acquisition, etc. After that, I can start playing with blade improvements. I'll post some more pictures as I get closer, but it's pretty slow-going. Too many hobbies..