I have not made anything lately, but I have used a few variac cores for transformers, winding turns over the core and orginal primary. I even made a choke for a welder. Had to cut one side of the core. That was about 8 inches across the diameter. Good to clean out the grooves in the track and give a coat of enamel. You can also use it as an autotransformer with better efficiency than the variac.
greg