" wrote:
We're making propellers over on the Chugger's Group.

I've been meaning to ask - what's a chugger (online urban dictionary gives
a meaning I'm not sure is the one perhaps intended,) and out of curiosity
where is this group?

Beer can stock will work. Ditto for shim brass, card stock and so
forth. Glue the pattern to the paper, cut it out with a scalpel. Or
glue it to the metal, SCORE the metal and flex the metal back & forth
until it breaks along the line of the score mark.

"Doesn't work," sez the Big Fella on the phone. He's been flexing his
templates for TWO DAYS and hasn't had one break yet.

Perhaps it's the scoring knife he's using? You probably already know about
this, so forgive me if this is redundant, but I've read good things about
the Olfa P-800 scoring knife ("Plastic/Laminate Heavy-Duty Ratchet-Lock
Cutter (P-800)"):

http://www.ch601.org/tools/olfa.htm
http://mthobby.pcperfect.com/ch601/chtools.htm

This is the online product page:

http://www.olfa.com/UtilityKnivesDetail.aspx?C=8&Id=58