Straight Blades
It is very important to have a straight profile to the non-curved side of the blades. See the following photo where the new blades are bolted together and are obviously not straight edged.
Another method is to tape the edges together as well as using clips, care should be taken not to melt the tape while heating. A little at a time is better than trying to do this all in one pass. It is also important to recognize the blade itself has a "melting" temperature and that you are trying to work within a'window'of heating to get good results.
The following pictures show the results, which are quite dramatic compared to the original profiles.