Here is the result. I hope my first attempt at posting photos works.
Material is clear white pine with a Minwax Puritan Pine stain and semi-gloss “rattle can” varnish.
I used a “bird’s mouth” router bit with my router table to create twelve staves for an open ended cylinder. I screwed 3 / 4” plywood to the base and attached a faceplate to the headstock. I cut a disk the same outside diameter as the inside of the cylinder and then fastened another larger disk to that one. A centered indent allowed me to use my live center on the tailstock. I turned it round, shaped the shoulder, and used a stainless steel wire to burn the seam. The lower diameter slip fits into the cartridge base. The projo just rests on the mouth. Total time – maybe 5 hours. I don’t really keep track of my time in the shop.
You may notice that the bottom “band” on the projo is “odd looking”. My sabot is in two pieces with the original “band” only holding two of the three pieces together. I discovered a drive belt for the roller on a Kenmore vacuum will hold all of the pieces together without looking that bad. Those extra “black lines” on the top of the sabot? A couple of large o-rings to hold the top together.
My next question concerns the finish. I have some naval training rounds of oak, so I kind of like the look of wood – although there is not a wood training round for the 120 mm (to my knowledge). On the other hand, I am a woodworker and is will be nice to say “Yeah, I made that part.” On the other other hand (It is easier to work on the lathe, if you have three hands.) I think the silver/aluminum look of the real cases looks good, too.
What does everybody here think? Leave it wood – or paint it silver.