1983 Hoover Turbopower U2194 semi restoration

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That fan you might be able to fill it with epoxy gradually in layers and lightly sand it until its leveled out and just do it over and over until its smooth. Get calipers to measure the taper of a new blade's thickness and try and build up the epoxy to smooth out and match OEM. It won't be 100% perfect but you might be able to get it close enough that it wont vibrate so badly anyway. There's also 3D printing but I'm not sure how well along 3D printed parts are yet for very high RPM/impact collision events. Also check around vacuum shops, there might be someone out there sitting on a NOS fan in their desk drawer.
 

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