Re: 1/2 hex shaft coupling
 

I would recommend investing in a hex broach in both 3/8 and 1/2 inch sizes. You will not believe how much they will get used. We needed similar couplings last year and could not find any so we made them by broaching 1/2 inch round shaft couplings

Re: 1/2 hex shaft coupling
 

We are using these this year, from Team 221 systems. They seem to be working out alright.

http://www.team221.com/viewproduct.php?id=137

The problem with buying a hex broach is you have to buy an arbor press big enough to use it. I know we don't have the space for that until next year when we get our new shop.

Re: 1/2 hex shaft coupling
 

Nice find! This would be easier to drill and tap than the steel sleeves I posted. They wouldn't work for us this year because we need something that can fit inside a 1⅛" diameter bore, but I will definitely keep this in mind for future years.

Cheers,
- Dean

Re: 1/2 hex shaft coupling
 

I prefer not to use set screws, generally. The only ones I've had decent luck with are the ones with knurled points to help prevent backing out.

If I were connecting two shafts together I would use a few spring pins, dowel pins, or cotter pins. Also consider axial shaft retainers. A little fancier, but they can work quite well.

Re: 1/2 hex shaft coupling
 

Buy a 1/2 inch deep well socket and cut the square end off.

Easy and cheap.

Re: 1/2 hex shaft coupling
 

Well why didn't I think of that last year. Good suggestion.

Re: 1/2 hex shaft coupling
 

Thanks but I think BJT actually beat me to it.