I have a home built airplane with a constant speed prop. The hub and all components are all usable but the original blades, made of extruded aluminum were prone to failure. I want to use the original blades to make a mold. Due to the shape of the propeller both side would have to be molded and the carbon fiber cloth sandwiched in between the two molds. Is there a way to do this and still vacuum bag and resin infuse the materials.
Also the finished propeller would be bolted with 3 bolts into root fittings that moves in the prop hub. Would it be best to laminate metal bushing into the propeller blades where the bolts would secure the propeller blade to the root fitting  or can the finished carbon fiber product be drilled out and be directly bolted into the root fittings.
Any guidance anyone can give to an individual with no experience working with carbon fiber would be appreciated. 

Hello fellow pilot.

Composite Airplane propellors are usually made in a closed mold and a pressure bladder inside is inflated to a high pressure that compresses the carbon to the mold surface. When completed they are balance and tested. I wouldn't dare try making a propellor. Unless you can test to destruction. I would never have a minutes piece flying with a propeller I have made. If a blade fails often the whole engine rips off and the CG change makes the plane unflyable. Your then dead shortly after. My advice is don't do it!

Fred

PS I fly and Earthstar JT2 pusher ultralight 90-100mph plus    

Hi. New here but a fellow aviator.