Need help designing keyway in gear

[Andy Brockway]

Originally Posted by sanddrag

EDIT: One more idea, maybe go with the 1/8" key but set it a little deeper in the shaft and don't cut the keyway so deep in the gear, but I believe it gets broached once without a shim and then again with the shim. Would anyone know the size of this shim?

Dave,

I do this on the 5/16" shaft with 12 tooth gears in my gearboxes. The shim is 1/32". Cut the keyway 1/32" deeper in the shaft and single pass broach.

Btw, I do not use setscrews with this method. I now use green loctite with the key with excellent results. I also used the loctite without a key on the dual motor DeWalt I built this past fall with no problems.

If you are planning on this gear sliding along the shaft, then obviously this information will not help