They also designed and carved their own wooden propellers, and had a purpose-built gasoline engine fabricated in their bicycle shop. They thought propeller design would be a simple matter and intended to adapt data from shipbuilding. However, their library research disclosed no established formulas for either marine or air propellers, and they found themselves with no sure starting point. They discussed and argued the question, sometimes heatedly, until they concluded that an aeronautical propeller is essentially a wing rotating in the vertical plane.[45] On that basis, they used data from more wind tunnel tests to design their propellers. The finished blades were just over eight feet long, made of three laminations of glued spruce. The Wrights decided on twin "pusher" propellers (counter-rotating to cancel torque), which would act on a greater quantity of air than a single relatively slow propeller and not disturb airflow over the leading edge of the wings.
Wilbur made a March 1903 entry in his notebook indicating the prototype propeller was 66% efficient. Modern wind tunnel tests on reproduction 1903 propellers show they were more than 75% efficient under the conditions of the first flights, and actually had a peak efficiency of 82%. This is a remarkable achievement, considering that modern wooden propellers have a maximum efficiency of 85%.
The Wrights wrote to several engine manufacturers, but none met their need for a sufficiently lightweight powerplant. They turned to their shop mechanic, Charlie Taylor, who built an engine in just six weeks in close consultation with the brothers. To keep the weight low enough, the engine block was cast from aluminum, a rare practice for the time. The Wright/Taylor engine was a primitive version of modern fuel-injection systems, having no carburetor or fuel pump.
The Flyer cost less than a thousand dollars, in contrast to more than $50,000 in government funds given to Samuel Langley for his man-carrying Great Aerodrome.