All,
I've made fine iron powder and epoxy cores and they will not saturate but have a inductance too low for us I think. It is much below 400uh and works nicely for 60hz but not much good at khz frequencies. Same experience with steel strips from an old microwave oven transformer. Since that experiment, I've bundled and put seven 1/4" ferrite rods through standard wire bobbins off the shelf and matched the ends with rectangular ferrite strips about five high. It works well and is cheap from ebay.
kb