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Originally Posted by sanddrag
I am no professsional machinist but I have done keyway broaching. It is basically a "staircase" of cutting edges and with each "step" it takes off a little more material. For the keyway, you start with the round bore, but the broach does the entirety of the slot. They have hexagon broaches too. You start with the round hole and on the broach may be like a foot long and on each step the cutter gets a little larger and a little more hex shaped and by the time it gets all the way through you have a full hex. I really thought there were Double D broaches, but I could be wrong.
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There are various kinds of broaches. We have one that was specially purchased to make a hole that fit the old Van Door motor shaft. Our sponsor provided it, so I have no idea how much it cost. I'm not sure whether or not it will fit the new Slider motor, though the output shaft is obviously different. Our sponsor also has a set of key way broaches which we have used occasionally. They all work as sandrag has described