If your client is simply looking to reproduce the propeller then he needs a "duplicator".
http://www.wood-carver.com/Gemini.htmlI would venture a guess that you are probably not making the best use of your time with replicating this
exact prop in CAD drawings.
There are many online resources that provide designs, even templates, for propellers.
http://www.aerodyndesign.com/PROP_10/PROP_10.htmIt's both a fascinating science and a beautiful art.
Your client is within his legal right to produce his own propeller for an ultralight or home-built aircraft.
Home-built aircraft have to receive an
Airworthiness Certificate through a series of inspections by the FAA.
Statistically, prop failure is not a widespread cause of aircraft accidents.
Edit:
By the way, don't take this as advocating making ones own prop.
That undertaking should not be taken too lightly.