How to Make Your Own Rim Chuck for a Wood Lathe

Cut two plywood discs the maximum diameter for your lathe from 36-by-36-by-3/4-inch sanded plywood using a bandsaw circle-cutting jig.

Tack the two discs together using four 1-inch long wood screws, and mount the discs to the faceplate of your lathe. Mount the faceplate and discs to the lathe.

Shape the outside edge of the discs using your lathe's parting tool by making small cuts along the edges. Keep lathe speed to fewer than 500 revolutions per minute (rpm). Sand to clean up the edges if necessary.

Mark three circles on the face of the discs while they rotate by using a pencil held against your tool rest. Make the first mark 1 inch from the outside edge, the second mark 1 inch outside the diameter of the faceplate and the third mark in the middle of those two marks.

Insert a drill chuck in the tail-stock, and drill one hole large enough to accept a No. 10 bolt through the center of the discs. If you do not have a drill chuck, then mark the center point with a pencil, and drill the hole with a power drill, ensuring the bit is perpendicular to the surface.

Remove the discs from the faceplate, and back out the wood screws holding the discs together. Place the discs side by side on a flat surface.

Mark one line across the center of one disc, intersecting the center hole. Turn the disc 90 degrees, and mark an identical line. Afterward, the disc should resemble a dartboard with circular lines intersecting straight lines.

Anchor the point of a compass on the disc's middle circle where it intersects one of the straight lines. Adjust the compass until its pencil end touches the outside of the innermost circle, and lock it in place.

Draw a smooth, sweeping arch with the compass between the inner and outer circle. Repeat this task for all four intersecting lines. When completed, the markings on the face of the disc should resemble a pinwheel.

Attach a circle-cutting jig to the base of a plunge router. Using the anchor points made by the compass as your guide, plunge the router bit into the plywood, and cut out a 1/4-inch slot using repeating, shallow cuts until the router bit cuts through the disc. Clean up the four slots with sandpaper if necessary.

Repeat the procedure for the second disc using the completed first disc as a template.

Flip one disc over. Using a No. 10 flat-head stove bolt, washer and nut, fasten the two discs together so they are held firmly yet can rotate against each other.

Thread one 1/4-inch long bolt, washer and No. 4 stopper through each of the four slots cut in the discs, and hand-tighten them.

Mount the faceplate back to the discs using the previous screw holes as guides.