To get there, we must make the disks first. I glued up five 1x4" clear pine boards. After, I made two passes on the joiner to true up the edges. Next I ripped the glue-up on the table saw to 3 1/4" square. Then, I tipped the blade to 45 degrees and took off the corners to make it easier to turn on the lathe.
Once I found the center, I put the six-sided block on the lathe and turned it. First with the rough gouge, then with a smaller gouge.
3/4 of the block is turned down to a little over a 3" dowel. Lastly, I used 80 grit then 220 grit sandpaper while turning and finish with 220 grit along the grain to take out cross grain sanding marks. The reason I did not turn the entire board is because I need something substantive to hang on to while running the dowel through the chop saw.
Each disk will be chopped off from this 3" dowel. I must finish with 18 disks so I planned for at least 22 cuts. That way, when I make a mistake somewhere down the line, I don't have to go back and start the entire disk making process again. It's got to be a production line concept. Each disk will be 3/4" thick and 3" round and will have a 2 3/8" hole in the middle so it fits around the PVC pipe. More on the lock later.
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