How to Package and Ship a Wooden Propeller
(Bubble Wrap Method)
A wooden propeller up to almost 9 feet in length can usually be shipped by FedEx Ground, based on its "dimensional weight", which is the calculation based on length plus girth for a non-standard package size.  Recently, FedEx Ground has increased their allowance for size up to a maximum length of 119 inches and a maximum dimensional weight of 165 inches, meaning that the length plus twice the width plus twice the height cannot exceed that amount.  (DHL will also accept large packages, but check on their availability to service your ZIP code first.) The goal  is to keep the final package small in total size, since the weight is usually not the limiting factor. Crating it in plywood adds additional protection, but will often take it over the size limits for FedEx and  then it  requires freight shipment instead.  The propeller has a great deal of inherent strength, so you really only need to protect  the surface and the prominent parts such as the edges.    This method also does keep it light, which makes it easier to handle in general, but doesn't necessarily save shipping costs since size, not weight, usually determine the rate.  I have found this method easy and reliable, and have shipped props internationally this way without problems. 
Materials needed:

Wax paper
Cellophane wrapping tape (available at U-Haul, Staples, and other places, and Saran wrap can also work).
Foam pipe insulation
Bubble wrap
Optional other padding such as foam, cardboard, carpet, etc.
Step #1  (Optional)

Cover the blades with wax paper and loosely hold down with cellophane wrap.  This protects the varnish and prevents abrasion or sticking, especially on the decals.  Don't try to cover it completely, just tack it in place, and avoid using any adhesive tape in these steps as it may tempt the receiving person to use a knife to cut it, and it isn't necessary until the final layer, where there is much less chance of damage to the prop when unwrapping it..
Step #2

Split the seam in the foam pipe insulation and spread the edges over the leading and trailing edges of the propeller.  Again, all you need to do is just hold it in place with the cellophane wrap.  The trailing edge is usually the thinnnest and the most vulnerable.
Step #3

Additional short foam pieces can be added around the hub.  Don't bother wrapping a lot of cellophane in these steps.  Save it for the final wrapping.
Step #4

Lay the bubble wrap over the blades and secure with some cellophane wrap.  If the roll of bubble wrap is placed lengthwise, it is usually possible to have it overlap at the leading and trailing edges for more protection there.

Other materials, such as foam wrap, cardboard, or even carpeting can be used in this step as well.

Once the bubble wrap  and any other padding is in place, go ahead with the cellophane wrap and just tighten it up and secure it.  This forms a "skin" around all of the packing material.
Step #5

After 3 or 4 layers of bubble wrap have been applied, use the cellophane wrap to create a "skin" holding the bubble wrap and other protection in place.  Some packing tape will help hold the end of the cellophane wrap down, but very little is needed here, and using it sparingly makes unwrapping it much easier. 

A "fragile" sign from the shipper may help alert the handlers to be a little extra careful, but the package is quite well protected this way.

I have found that FedEx Ground will take larger packages than UPS, and the size of this propeller is even close to FedEx's dimensional limit.
12/11/04
12/18/07
Approximate Costs:  (2004)

Materials - $25  (most is bubble wrap, which is reusable, however)
FedEx Ground - usually under $100 coast to coast, less for shorter distances.
Shipping:

      FedEx and DHL can pick it up, or you can save a little expense by delivering it yourself to their location.  See first paragraph at the top of this page  for FedEx info.
NEW - Step 4A
I recently found that a cardboard sonotube (used for concrete footers and available at building supply stores) can be easily cut into strips and placed over the hub and the leading and trailing edges to give considerable added protection without adding much weight or size.  It goes over bubble wrap and then I add addtional bubble wrap on top of that.