Try testing the thickness of the plastic blades. This year, for the first time, we have discovered variations in the thickness ranging between .007” and .010”. It appears that the plastic stock is not being kept consistent as each different thickness material is that thickness over the entire blade.
The best way to determine best is to fly them.
You are right. I can even feel the difference by hand. The measured thickness matches your range.
More questions, what's the tolerance between two blades in pitch? We found 5 degree difference at the widest chord but 1 degree difference at 75%. Any method for us to test dynamic balance of the prop? I tried rotate with rubber band and winder, while hand holding the prop hanger, cannot tell.
Thanks for your help,