Here is my finished pot chuck.
A Pot Chuck is used to hold work which does not match up with the jaws on your Lathe Chuck. Here is the finished pot chuck with a piece of 0.5" stock.
Step 2: Pick a Piece of Round Stock a Bit Larger Than Your Work Piece
In this case I want a pot chuck for 0.5" square stock. I am using a 1" diameter bit of Aluminum for my pot chuck. This is a little thick, but it turned out fine.
Step 3: Drill an Initial Hole on the Lathe
I used a 1/2" bit to remove the bulk of the material.
Step 4: Use the Boring Bar on the Lathe to Finish the Hole
In my case I needed a 0.71" diameter hole for my 0.5" stock.
Step 5: Check for Fit
My stock fits snugly. Yay.
Step 6: Cut a Slot Through the Edge of the Pot Chuck
I used the mill, but a bandsaw would work fine.
Step 7: Complete Pot Chuck in Use
Make sure that your jaws are all getting grip on the pot chuck. Especially, don't have a jaw come down on the slot in the pot chuck.
And have fun!