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DIY Shaft maker.

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Morgan:
Next drill holes through both 2x4's. I did 23/64 11/32, and 5/16. This leaves a rough surface that requires sanding, so I'd drill 3/8, 23/64 and 11/32 if I had to do it again.

Morgan:
Next I drilled through one of the 2x4 pieces with a 5/8 bore bit. It was biggest I had and takes about a 7/16 square blank.

Morgan:
Glue to plywood plate centered on cut line. Clamp plate to saw with hole you will be using centered with blade arbor.
By hand turn your ripped blanks into the 5/8 hole raise the blade till it just starts cutting and continue to raise blade a little at a time till it turns blank down enough to enter hole on opposite side. Pull blank out and chuck that turned piece into a drill. Spinning the drill and feeding slowly slowly through jig. works ok. Not perfect but it'll do.

Morgan:
The tighter fit your blank is to the first hole the better, and the tighter fit from the blade into the second hole, the better. The second hole will burnish the roughness off if it is tight enough.

Knoll:
COOL! Thanks for taking the time.

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