: Why would he make a Ring knowing that the One, were it to re-surface, would be its master?

: Perhaps he thought that the one was lost forever?
: Perhaps, in his studies, he discovered how to forge Rings of Power which would not be subject to the One?
: Perhaps, as had been suggested before, the One Ring only controlled the Rings which were already in existence when it was forged and Saruman, knowing this, had no fears that his Ring would be ruled by the One?

: I favour the last option.

As do I.

: A number of Rings were forged before the One and, indeed, before Sauron had a hand in instructing the Ringsmiths. I think (and it's just my opinion) that Sauron forged his Ring specifically to control the main Rings of Power that he had been involved in making. He could 'read the minds' of the wielders of the Three (and vice-versa, according to Galadriel) but not control them. Saruman must have known about this and therefore was not worried about being controlled.

Well not exactly. The wearers of the elven rings torn their one's off didn't they, just so as to prevent Sauron from controlling them. Where as the wearers of the dwarven rings, being dwarves, were un-coercable anyway. The only ones who were mastered were the wearers of the nine rings for men and that was why nine ring-wraiths were soon knocking around. As soon as Sauron lost his ring, the elves could then start to use there ones again. I am sure that was the case, but then my memory may be failing me (again!).

: However I don't know why Saruman's mind wasn't laid open to Sauron as soon as he began to use the Ring. Or perhaps it was, and that, along with the use of the Palantir was how Sauron overcame him.

Well, connected to the conclusion that we have come to, as ststed above, Saruman's ring was not (IMO) subject to the One and therefore there would be no reason that Saruman would either be able to read or contact the mind of Sauron through it, or Sauron do the same to Saruman. That one must be down to the Palantir.

: Sorry for rambling.

Cheers

Padster