A method of repairing a vane cluster for a gas turbine engine includes attaching a first registration block to a salvageable airfoil segment of the vane cluster, machining a face of the first registration block relative to datum surfaces of the vane cluster, removing a damaged airfoil segment from the vane cluster, adding new material to the salvageable airfoil segment, joining a replacement airfoil segment having a second registration block to the salvageable airfoil segment to replace the damaged airfoil segment, removing the first registration block, and removing the second registration block. The respective first and second registration blocks of the salvageable airfoil segment and the replacement airfoil segment are aligned in a configuration substantially identical to a configuration of the vane cluster prior to undergoing repair.