pic: Homemade Keyway Broaches
 

Re: pic: Homemade Keyway Broaches
 

beautiful! thanks for showing us such a neat idea

Re: pic: Homemade Keyway Broaches
 

very slick! now if only there were a way to make hex broaches like this...

Re: pic: Homemade Keyway Broaches
 

If I get access to a manual lathe with a three jaw chuck then that will be my next project...

Re: pic: Homemade Keyway Broaches
 

One year at GLR we had to put a keyway into a sprocket, and we didn't have a broach or a press in the pits. So we taped about 5 hacksaw blades together, and slowly cut the keyway into the sprocket. Took awhile, but worked out just fine.

It also cost us 5 hacksaw blades.

Re: pic: Homemade Keyway Broaches
 

Here is a photo of what else I did. I keyed two of these hubs as well as cutting a key slot in the drive shaft with a Dremel carbide cutter. Took a while, but it works!

Re: pic: Homemade Keyway Broaches
 

I've actually done this same thing but to make a knurled surface.

Grind off all but one flute, put the tap into a vertical mill and make a pass on your piece (cutting along the side, obviously). Rotate the piece 90 degrees in your vice, and make a pass again. It'll leave you with a nice knurled face that's good for gripper jaws on end-effectors.

Re: pic: Homemade Keyway Broaches
 

I love that idea and it gives a good use to old taps!

Like they say, "Necessity is the mother of invention!" :)

Re: pic: Homemade Keyway Broaches
 

Not bad Gabe... not bad at all! :D
I'm impressed.