Options for replacement blade/vane for self-steering windvane

[Sailon1]

The vane on my CYS (vintage system, made in Michigan) needs
to be replaced. This wing-shaped vane was made from a solid piece of aluminum, folded in half with a piece of styrofoam in the center. Weighs
less than 4 lbs, 48" tall, 18" at the base tapering to about 4" at the top.

I had one quote for $500+ to manufacture an exact copy, but there are less expensive options, I'm sure . . . plastics, wood, sunbrella around a frame of some sort?

Your suggestions will be very much appreciated.

[Copacabana]

I think any of those options would work, providing the weight and shape stay the same. My Windpilot has a stainless steel frame with a nylon rip-stop sleeve over it. Other windvanes use thin plywood. I think I'd try thin plywood first- it's cheap and you can make up a few spares if it works out.

[Spot]

Hello Sailon1,
The foil section could be cut from EPS 'white styrofoam' like a RC airplane wing with a hotwire and airfoil templates. CNC cut foam is another option.

After that you would need to make a base to hook the foil to the rest of the steering mechanism. To me the joint between base and foil is the real engineering issue. I would consider G10/FR4 fiberglass board for this.

Then cover with fiberglass cloth and epoxy resin like a surfboard or other composite project. The glassed skin will add strength to the project.

Pictures of the current 'situation' might inspire more comments.