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I tried to use my homemade vacuum chuck on a green turned bowl and there was a little warp preventing good seal. I took a piece of plain foam and cut a hole to allow vacuum to reach wood and laid it on the chuck and then the bowl. The extra thickness allowed compression to get a good seal and I could then remove the tenon. Simple trick that I must have picked up somewhere in the past and necessity caused me to try today.
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Good creativity !
I saw a commercial vacuum chuck (about 4" D) that had walls about 3/8" thick or more. That allowed for a larger radius edge that would be less likely to cut the foam at the contact ring. Since the homemade are made using PVC couplings, has anyone tried gluing in a section of PVC pipe to allow for a thicker wall and a larger radius. Just a thought, but I think I might try it.
Been doing this for years with a standard PVC fitting, works fine. Get the closed cell foam at Hobby Lobby