This paper details, assesses and validates a technique for the replication of a titanium wind tunnel test aerofoil in polyurethane resin. Existing resin replication techniques are adapted to overcome the technical difficulties associated with casting a high aspect ratio component. The technique is shown to have high replication fidelity over all important length-scales. The blade chord was accurate to 0.02%, and the maximum blade thickness was accurate to 2.5%. Important spatial and amplitude areal surface texture parameter were accurate to within 2%. Compared to an existing similar system using correlation areal parameters the current technique is shown to have lower fidelity and this difference is discussed. The current technique was developed for the measurement of boundary layer flow 'laminar to turbulent' transition for gas turbine compressor blade profiles and this application is illustrated.