Broaching a bevel gear

[matthewdenny]

We are planning an off season design project. It involves using a Bevel box ( http://www.andymark.com/product-p/am-2622.htm ) Unfortunately we need to use 1/2" Hex shafts as both shafts, and this gear box uses 3/8". (There use to be a 1/2 Hex version at Andymark, but it has been discontinued.)

My question is if it would be possible to broach these to 1/2 hex. Or alternatively, find a source for gears that would work with out broaching.

[asid61]

I don't think you can broach those for 1/2" hex. The gear is physically too small it looks like, but I haven't opened up the step file to check.
McMaster sells 1/2" hex boraches if you need those though.
Are you certain you can't just plug one of those Andymark 22t sprockets on there with the 0.75" hex hub? I forget the name, but the hubs can be swapped out for pretty much any size.