This paper describes the design and development of a precision calliper system to measure the surface profile of an outboard marine engine propeller blade. Several instruments that are commonly used for measuring the surface profile of a propeller blade are reviewed in this paper. These include the pitch meter, the profilometer and the computer numerical control coordinate-measuring machine (CNC-CMM). However, the operating practices and availability of different facilities in industry necessitate a more cost-effective approach. An alternative method using a precision calliper system is therefore proposed. Details of the design criteria, principles of operation and the testing and verification of the system are presented. The paper concludes that the precision calliper system is a cost-effective method for measuring the surface profile of a propeller.