Abstract: A method for replacing airfoil components includes the steps of identifying a portion of the airfoil to be replaced, removing the portion by a nonconventional machining process, such as continuous wire electrical discharge machining, and forming a replacement member utilizing a similar cutting process. A cutting path utilized to remove the portion to be replaced and to form the replacement member includes interlocking projections and sockets and may include one or more tapers along the cutting path so that the portion may be removed only by lifting in one direction. In cases where an entire airfoil is replaced, a first projection may be tapered in one direction while a second projection is tapered in an opposite direction so that the airfoil may not be removed as long as its adjacent flowpath walls are fixed relative to one another.