I need a plan.

[Transformer]

Well I decided to try the mandrel approach. Rough cut the aluminum on my resurrected band saw, began to make the mandrel when.... my motor stopped working. Probably only about 6 hours of run time as it is a new machine, but the project is on hold until I solve that problem.

Thanks for all the input.

 

[Sharky]

I'd cut them on a drill press with a hole saw.. Stack all the flat pieces together on top of a piece of wood and clamp the whole aluminum sandwich down to the drill press table and drill away with a hole saw ID that gives you the dimension you need. Or use a fly cutter, same scenario.

+1

Cut oversize with a hole saw, the pilot bit is only 1/4" so you can drill to a tight fit on whatever size mandrel you make. Stack all the disks and use the tailstock center. Cut all disks at once and save setup/changeover. you can make the mandrel out of all thread ot round bar and thread the ends to check-nut the disks tight. If the center disks want to slip, a bit of carpet tape between the disks will lock them together.