I wouldn’t bother with air core. Ferrite beads allow you to use old calibration. If you make 1:1 balun just by threading coax through toroid, you can use old calibration as well provided it’s the same coax. Keep in mind minimum bending radius of coax. There are other designs, like using twisted pair on toroid

I’ve seen people using PE-Al-PE pipe for variables, this gives you layer of good dielectric (polyethylene) in dimensionally stable form. One connection is aluminum layer inside the pipe, and for the other you’ll have to figure it out on your own. Retuning might be required anyway within the band (magloops are narrowband) Common way to make variables is to bolt two of them in series, so that no sliding contact is used, moving part is the same for both. This is good for high voltages also but i’m not sure if you’ll need it