Hi,
About once a year I make about 200 disc out of MDF. These disc are
3.25 inch in diameter, 1/2" thick with an axial 3/8" hole. The rim of the disc has a groove 1/4" deep and 1/4' wide around the circumference so that from the side a cross-section looks like:__ __ | | | | | |__| | | | | | | | | | | | | | | | | | | | | __ | | | | | |_| |_|
I cut the MDF into squares and then gang cut these squares into octagons. Up to this point things go fast. Next,I mount about a dozen octagons at a time on a threaded rod which is held in a metal turning lathe by a three jaw chuck and a live center in the tailstock. Things do no have to be very precise so I can eyeball the side-to-side position of the groove and use a stop to control the depth. My cutter is the width of the groove. I have colored paper between the octagons so that I can more easily see where to cut the groove.
Is there some easier way to do this? Molded solid platic probably could work, but the cost for a small run might be high, I have thought of using a hole saw and cut two thin (0.125") discs 3.25" diameter with a hole saw and a 2.75 diameter disc that is 0.25 thick. But my experience with hole saws usually involve lots of fighting to get the disc free.
Any ideas? Thanks
Roger Haar