Here is where it all started which was with a picture that was enlarged on a copy machine to the approximate size I wanted. From here I used calipers and started to get the dimensions for all the pieces. 
 

After I had the sizes, I could start drawing the pieces in my CAD-CAM (Computer Aided Design, Computer Aided Manufacturing) system at work. Here is where the computer is used to make the machine programs for the CNC (Computer Numerical Controlled) machines. The CNC Lathe was used first which made all of the pieces except the Knight.
 

Here is the Lathe I used which is a Mori Seiki SL-20 and me running it. For those that don't know, this machine makes things round. It uses the code that the CAM system wrote and then the program is downloaded to the Lathe with a laptop computer. From here you set-up all the tools that will be used and then run it. It repeats very close so it's easy once you are all setup to make lots of parts that are all the same.
 

The material used was 6061-T6 Aluminum. I used 1" diameter material for the Pawns and 1 1/4" material for all the other pieces. I ended up using 12 feet of each diameter which was enough for the two sets.
 

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