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I took these photos in -99 and boy I'm glad I did!
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First, measure the diameter of the engine intake and cut styrene stripes to length slightly less than half of the engine diameter. This will ensure that opposite blades won't touch each other when placing to the template.

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Take some low-tack masking medium (Friskette for example) and tape it tightly against the table, adhesive side up. Place cut strip to masking surface. Adhesive of the masking medium prevents strip from moving when cutting strip diagonally.

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Cut the strip.

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Next, you have to draw or print fan template which is used for aligning fan blades. Use template under mask (adhesive side up). Now you can start placing the blades in a given order. Third set should be between set 1 and 2 and so on. You need patience!

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After all blades have been set, a shaft is attached to the blades. You can use brass tube, but styrene is a better choice. Don't use larger tube than fan hub is or you will see end of the shaft when viewed from the front! Template used for aligning.

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Let the glue cure properly before continuing! This is critical as mating surfaces are very small and blades will snap off easily.

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You have the last step to be done yet: removing the fan from masking medium. Remember when I suggested using a low-tack mask? I mean it!!! Otherwise you will not be able to remove fan from mask without damaging it. Good luck!

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