Paramotor Propeller Mold Fabrication & Damage Repair Composites Carbon Fiber & Fiberglass

[@32laurens]

Very therapeutic... that mould is a work of art in itself.

[@jorgemancuso1315]

Thank you Kyle for the masterclass! It has been really useful to me.

[@abelferia1]

I can work the lathe, milling machine, tig mig stick welding, press brake, and more, but let me take my hat off to you buddy. keep making videos like this one where everybody gets to learn how it's done, God bless.

[@kyleoglee]

A man with your skillsets could appreciate that of all the things I do, I find a successful sewing project satisfying on a lathe and mill satisfaction sorta level.

[@brunodesousa3772]

I’m loving these technical repairs Kyle! 👌🏼

[@kyleoglee]

Thanks Bruno!

[@davidyoung518]

The Wizard sharing his skills and tricks for all his inspiring apprentices'!

[@kyleoglee]

I've been tripping out since my son told me that jive. I want to grow a big beard now, and wear a pointy hat...Oh, and carry a big stick around too. ha ha. Still inventing potions, and flying around on the regular too!

[@falconron4217]

Some nice work there Kyle, The best you-tube university education yet

[@barrywebber100]

That's some good skill on show there, you make it look easy but for many people that would challenging to do well. Having a well equipped work shop is a great asset. Thanks for posting.

[@joshperryppg]

Man, I can't be first when you release a video at 8am on a Saturday! I'm sleeping! Well, at least now I get to enjoy my coffee with a Kyle O' video!

[@robroy25]

A man of many talents...the Adam Savage (Myth Busters) of paramotors....great content big K....Cheers..

[@kyleoglee]

Thanks Rob, I love Adam Savage content too. I've been a fan of his since Mythbusters, and now his Tested channel on this platform is very good.

[@davidhayman7623]

Hi Kyle, thanks for time and generosity in sharing your knowledge and processes. Great video keep it up!

[@woodystarkey2329]

Woody here no the other woody twisted wind woody great content love the repair videos love to see more of that kind of repairs peace an love thanks

[@kyleoglee]

Right on Woody!

[@FrugalMooney]

As always, good content. I love the shop videos.

[@jb92563]

This is a great instructional video and it will give pilots stuff to do when the conditions are not right for flying. You are truly spreading skills and knowledge and its definately being appreciated. Frankly with all you do I don't know where you find the time to not only do all this work but also video and produce all your content. I have an eProp that had the last 3" of a blade removed by a loose gas cap but it sounds like that might be too much for a repair like this? I wonder if there is a use for busted props that are beyond repair, maybe wait till you bust another blade and make a wall clock out of it, or a mean looking fan or a windmill.

[@skysportsusa5010]

Awesome edit! Thank you for taking us through the process.

[@JohnHansknecht]

Impressive! Thanks! Further up the prop, are these foam core? I haven't broken one far enough to know. I assume they are because of the weight.

[@kyleoglee]

Negative on foam from Helix propellers. There is a bit of balsa at the hub, and then unidentified composites throughout the structure. I've dissected one a few times during a necropsy.

[@shahram677]

Hey Kyle,nice videos Do u have any video for homemade balancer? Sean

[@The_real_Dr_mysterious]

Is it possible to put three propeller together to make one propeller for a more efficient aircraft?

[@goldwingerppg5953]

Great video! Do you ever spray clear coat for weight to balance?

[@bjornplanetorz2963]

Nice one Kyle, nice explained video. 👍

[@justbikewatch]

Amazing content!! Thanks Kyle!!! Good mold technique... just a question, for balancing, what do you think about drilling a hole and add a small solid weight to the tip edge of the prop? I've seen many people doing that, any disadvantage or just preference?

[@kyleoglee]

It can dislodge and move. Especially with a foam core prop.

[@SmittySmithsonite]

Now that's an ingenious setup! I wonder if I have the patience for that, without making a pile of scrap over 4 weeks, lol. With my trike, I'll hopefully be less likely to need to build one. HOPEFULLY ... 😉

[@kyleoglee]

There were many disasters learning how to do mold making. Will definitely take you more than 4 weeks!😆

[@SmittySmithsonite]

@@kyleoglee -Ahh, gotcha! I figured that couldn't have been easy.

[@DougBow96]

Really cool, thanks for sharing your techniques. I like your balancer! :)

[@gabrielacristancho1161]

hello. What thickness of carbon fiber cloth do you use?

[@YankeeinSC1]

Nice one Kyle. This, or something similar, is a must for anyone running a PPG school. So... I want to design a new quick release prop hub that would be at an incredibly low cost point, but it will require the cooperation of a prop manufacture to incorporate the concept into their hub. The parts would have to be designed to work together vs. adapting the coupling to existing bolt up designs. Alternatively I could set up to build a line of props, but that's not where my interests lie. Your mold came out good enough, but I have to ask, do you know if the major manufacturers (Helix and eProp) are doing much sanding after the cure?

[@paraglidingtalk]

I blasted my first prop this weekend. I am getting my stuff together to make a mold of the new prop that is in the mail. I am interested in getting the register key down. I didn't see in the video the other half of the mold. Did you just form some little bumps to fit in the holes?

[@kyleoglee]

I've done many different keying methods. Most recently I've been using plasticine clay, and putting the female divots into the first half, then pouring the male in with the second.

[@aaroneye86]

Very cool process, great repair!

[@David65702]

Very educational.

[@kyleneel6382]

Hey kyleo great video! If possible could you explain what you used for the balancing that was tied to the strings for the prop? Is it just a simple piece of metal we can buy or was it milled for just this use? Trying to get this setup like that to help repair props at our school!

[@kyleoglee]

I made the hub on the lathe.

[@kyleneel6382]

@kyleoglee oh well darn. I really appreciate the reply! Especially on a older video! I'll use what you showed and make it work! Thank you!

[@CashCowCellular]

So glad my name is neither on those propellers LOL. 😂🥳 Great content!

[@joshbarnes5784]

🤔 are you going to start possibly offering repairs? I have a 130 helix on a moster that needs some love.

[@kyleoglee]

Been repairing props for years Josh!

[@joshbarnes5784]

@@kyleoglee mind if I send you a message on Facebook?

[@MikeFlyItAll]

That's awesome bro... thanks for sharing...

[@rogerr1296]

Not sure if it would work with what you are doing but, working with epoxy in woodworking you use a butane torch to pop the bubbles once they have risen to the top. I'll have to try the heat gun just for shits and giggles.

[@kyleoglee]

The gun is a bit more controlled. You can overheat with a torch easier, but not someone with your skills. Still, I think you'll like it better.

[@rogerr1296]

@@kyleoglee My skills consist of trial and error or, in my terms, screw up and cuss a lot and on occasion make a screw up that I can make look right. 😂

[@damianmchale7543]

Brilliant video 👍🏻

[@kevincollins8014]

This was very interesting thanks for sharing.

[@paulgosney3544]

Hi Kyle, I'm interested to know why the Atom's seem more prone to end up with prop damage than your Moster's.

[@kyleoglee]

More first launch attempts. Everyone gets to give an 80 a go before moster.

[@alejoal07]

How do you figure out where to add weight, whether near the tip or near the hub? the same amount of added weight will have a difference effect on static balancing depending on position, that's where dynamic balancing comes into play but that seems like too much of a hassle in out sport

[@kyleoglee]

I simply use my finger, and the amount of pressure required to locate the optimal spot for the ballast injection. If the shape is symmetrical, and the static balance is spot on, I find zero dynamic vibration present. The molding is also very crucial in assuring this outcome.

[@alejoal07]

@@kyleoglee thanks! Amazing work BTW

[@Iskconcape]

Hi Kyle, have you ever repaired a helix prop with a clean break about 3/4 way down from the tip, can it be repaired safely or is it irreparable because of the stress at the point

[@leoyoman]

Structural repairs below 2/3rds from the root is not advised

[@aussieparamotorman9931]

Awesome job!

[@kyleoglee]

Thank you kindly sir!

[@RunIntoTheSkyNonprofit]

Great video

[@davidhawkins3820]

Where can I find the propeller balancer? I see the product PropTop but I have yet to find it for sale.

[@kyleoglee]

I made this one custom.

[@pinevalleyoutdoors3788]

What did you inject into the prop??Thank you

[@kyleoglee]

Thickened epoxy.

[@FreshMOG5760]

Y not make the full package

[@paiisebutton6322]

good :) can I ask something? what material of porp can not be repaired ?

[@kyleoglee]

I suspect anything can be repaired.

[@paiisebutton6322]

@@kyleoglee yeah I'm with u but I mean just case of 'minor repair'. Any prop can be repaired by major repair but in field, can not be done that repair.

[@kyleoglee]

@@paiisebutton6322 Propeller field repairs are a fools game. Switch it out with your back up propeller, and bring it back to HQ for a proper repair session is the way of the Jedi.

[@robertstimeparamotoring5313]

you are the man !

[@kyleoglee]

Nah, heart of a 15 year old teenager. Never really made it much further! ha ha.

[@BSmithPPG]

Really interesting video 👍🏻👍🏻

[@scaviator4207]

Hey Kyle, what do you charge for prop repair?

[@joshbarnes5784]

GOOD CONTENT 👍

[@kyleoglee]

I put in some effort on this one! ha ha! I give it mediocre status ;)

[@turkeyphant]

Where on earth do you get so many broken props?

[@kyleoglee]

I run a paramotor school.

[@FreshMOG5760]

Yo nice content man can u make more

[@stealcian74]

Does anyone sell molds, I would love to buy one for the mostar 185 e prop 125cm

[@kyleoglee]

I would, but eprops are not conducive to repair. Too thin.

[@thomasnappo6309]

Your awsome bro..

[@flyjtaylor]

Homemade balancer?

[@kyleoglee]

Of course John!

[@flyjtaylor]

@@kyleoglee I’m jealous! You have ALL the cool toys!

[@kyleoglee]

@@flyjtaylor My cool toys make their own cool toys! Toolmaking is the real alchemy of this new world!

[@flyjtaylor]

@@kyleoglee I certainly agree! My biggest observation is the value of the tool between the ears! Ours seem to have the same blueprint, but yours seems to have a way of materializing! Keep doing what you do so folks like me can live out our dreams thru it!

[@don7294]

Kyle, thanks for sharing and stay safe!

[@akbarshoed]

You are an awesome guy, you know that?

[@joeowens7585]

👍

[@RonBesse]

Totally awesome!!! 🙂 Oh yeah, I'm not first.

[@kyleoglee]

Thanks Ron!

[@justinmalone1076]

Something tells me this guy’s really involved in drugs.

[@awaitingthetrumpetcall4529]

You're pretty good at balancing props but you're a pharmacist. You 'have' to be precise.

[@kyleoglee]

Pilot's are pretty good at precision too!

[@michaelkennedy2528]

I see one coward gave a thumbs down and did not leave a reason for it, typical cowardice move.

[@kyleoglee]

He strikes again!😆

[@GDFred88]

@@kyleoglee I'll change it to a thumbs up if you'll repair one of my props! LOL! (Not really me! Hehe!)

[@SmittySmithsonite]

The thumbs down guy - he's everywhere, hiding behind his computer screen as usual!

[@JohnnyVegasStudio]

bet he flys a flat-top :)

[@pinevalleyoutdoors3788]

@@JohnnyVegasStudio I fly a flat top and dominator..and my equipment.... Love this video. Thanks Kyle...

[@Giroskop]

Makeing mold from carbon fiber is wasteing of expansive material, you can do it just from fiber glass and it will be still wery strong. It is also better to make second half of mold without removeing blade from first part of mold. Looks very unprofesional, adding material on a tip of propeller is very dangerous, added material can still brake up and fly off during flight! He is useing way too much resin and just 2 layers of carbon. It is joke, dont do it guys....

[@kyleoglee]

Been doing this for years. No failures so far. Come back to complain after you have repaired hundreds of propeller tips sir.