[sanddrag]

Originally Posted by dlavery

p.s. you can indeed broach a square keyway in a blind hole, it just takes a different technique than using a conventional broach set.

I'm guessing you'd have to grind a tool that is recangular in shape that is the thickness of the keyway you want. They you'd grind it sharp on the edge (sorry, I'm not describing this well). Think something like a lathe groove cutting tool. Then, I'd rig up something to put it in the spindle of a mill, align it to be parallel with a mill axis (lets say x), and lock the spindle with the brake and/or a very low gear. Then, with my gear already positined in a vice or whatever such that the ground cutter is directly over the gear diameter that is parallel with the x axis, I would make sure the y axis is locked in place. Then, I would proceed to move the cutter into the gear just a little bit, and pull down on the downfeed handle. Move the gear into the cutter a little more, and pull down once more. Each time, you "shave" off a little bit until you get the depth you want.

Is this correct for the most part?

PS. Substitute "wheel" or anything else in where I said "gear"