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Tim, what thickness of metal did you use?

Here is a link to all the pics...
Domed-washers - a set on Flickr

Have it run in slide show mode for better closeups.

I hope this gives some good ideas. :)

Perhaps another way to turn down the diameter of the washers would be to put them on a 256 bolt, cinch them down with a nut, mount it into a drill chuck and use a file or sandpaper.

In the future I will try to find some threaded rod so I can tighten up on the collars to prevent the free wheeling.

Here is a pic of the collars w/set screws...

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This is the result........

124630124631

Then off to the sander....

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But the wheels were freewheeling to much so I took off the brass tube and cut some thick aluminum tube so there was more friction against the collars so they...

Then I put them into the doming block

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after the doming block ( sorry, forgot to take a pic but it cleaned them up a lot)

I cut some 1/16 brass rod, some 1/16 brass tube and the...

OK, here are the pics of the process. This is pic heavy.

This is the tool, available from Harbor Freight.....124620

I used a big die for picture clarity and punched out a bunch of washers from...

Sorry that I don't have pics for this......

To reduce the diameter of the washers put a bunch of them on a 1/16" rod. Cut 2 pieces of tube with an inside diameter of 1/16". Each piece about 1/2"...