Improved techniques are provided for manufacturing a toroidal arc segment piston for use in a fluid pressure responsive rotary actuator, and for forming an actuator housing defining an arcuate chamber for receiving a rotary actuator piston. A moldable polymeric material is positioned within an arcuate master chamber in a piston-forming fixture, and a metal piston core is rotatably mounted to the fixture. The piston core is rotated to displace the polymeric material and form a sheath about the piston core. After curing, the piston core and sheath are rotated out of the arcuate master chamber, and are installed in a rotary actuator housing. A master piston may similarly be used to form a polymeric lining which defines the chamber for receiving the piston in the actuator housing.