Thanks black85vette, Davo J, Anzaniste, and awemawson!
Anzaniste, I haven't tried a hole saw on something this thick before. I did do a tube sheet in my drill press that way, and it really wasn't turning slow enough. Quite a bit of screeching and smoke, despite sprays of coolant from a bottle but it got the job done. Very unpleasant though.
I suppose that it could be done better if it was run on a mill at slow speed, but I think it might take a while. You would still have to re-mount on the 4 jaw in the lathe and bore out to a close sliding fit.
On my lathe, I think a hole saw might be hard on the MT-2 taper tail stock and Jacobs chuck. But maybe I'll try it some time.
My ideal would just be to cast these in iron when I have the CI casting ability (coming up shortly). Then the hole is simply cast in. Doesn't even need a core. Still has to be bored, though.
awemawson, I agree. I'm not proud of the finish. Hoping Rob will at some point reveal all in a tutorial. I don't own a surface grinder, or a belt sander, and don't have a buffing wheel set up. My tool grinder needs both abrasive wheels. But I will work on these holders further by hand to get them more presentable when the whole set is done.
Today I have an interesting holder to make. Hope it works out. Will let you all know.....
Thanks again guys!