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#16
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Re: Hex Broach Options?
For that amount of work, I think I'd just buy a broach. And how do you grind the allen key without losing some dimension? Surely the end result would not be able to freely slide over a piece of hex stock like it would had it been done with a real broach.
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#17
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Re: Hex Broach Options?
In this case, they were only grinding the end of the allen key. Think of it as a broach with one edge. Similar to a mortising chisel attachment for a drill press.
A clever machinist/toolmaker can do amazing things with rather simple machinery. In this case, the idea is to make a real broach. Even if you were to taper it and make several steps, it's really only the final step that makes much difference. Whether it will work or not depends on the precision of fit required. |
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#18
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Re: Hex Broach Options?
This year our team faced the same decision. Spend the money and get a hex broach or find a different way of locking it to the shaft. We decided to spring for the broach because in the long run we will most likely use it several times over the next several years. They are expensive but we feel we will get our money out of it. If you think you won't use it more than once or twice then I probably wouldn't buy it.
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#19
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Re: Hex Broach Options?
And here is the OTHER answer...
EBAY!! I just searched for broach hex on ebay, and found a few. Just need to get lucky - but they can be found for cheap. |
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#20
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Re: Hex Broach Options?
Go to a waterjet shop.
Ask them to demo their waterjet. By cutting some 1/2" hexes in 1" steel. And ask if you can keep it as a souvenier. Proceed. |
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#21
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Re: Hex Broach Options?
buy a 3/8" hex and go!
$130 is not all that expensive if you consider all of your options. if you buy the right size, a size that will fit all your applications then that one broach will probably last you your entire life. as long as you use the broach correctly and feed it plenty of high quality lube then you'll be fine. we do a lot of broaching in our lathe. put the material in the chuck and the broach in the tailstock......lock, crank, broach. very simple. no more keys, no more trantorqu......just cheap hexagon stock. our 3/8" hex broach is going strong after hundreds of broachings. |
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#22
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Re: Hex Broach Options?
We use 3/8" (used in kit transmission, too), 1/2", and 3/4" (used in kit transmission, too). We added the 1/2" to our arsenal this year to drive the shooter wheels.
The 3/4" was expensive (like $400), but the 1/2" and 3/8" are less than one night at the Omni. These broaches will last you a very long time. We do not use keys anymore, just hex broaches and very cheap hex stock. This solution is a very reliable and maintenance friendly design. |
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#23
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Re: Hex Broach Options?
Pardon my ignorance, but for those teams that use hex shaft, what's the standard practice for when it comes to putting bearings on a hex shaft?
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#24
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Re: Hex Broach Options?
For us, the beauty of using the metric system (whenever possible) is that 10mm bearings work great with 3/8" hex (look at kit tranny hex shafts). 1/2" work great with 12mm or 14mm bearings. 3/4" work with 20mm bearings. I can show you pictures and cross sections when I get more time.
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#25
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Re: Hex Broach Options?
I solved this problem once by buying these and welding them to some sprockets. It worked very well. They are available from Small Parts .
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#26
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Re: Hex Broach Options?
Paul is more brave than I.........
we use double bushings! to pass a 3/8" hex through a bearing we buy a bronze bushing from mcmaster at 3/8" ID, 1/2" OD for about $0.12. we broach it........ then stick the bushing and the shaft into a standard .5" ID bearing. voila! one hex stuck through a round hole........everything is true and round. putting the hex through a bearing is a fine solution, but for high load application i prefer to have the double bushing to help spread the forces around. |
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#27
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Re: Hex Broach Options?
Quote:
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#28
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Re: Hex Broach Options?
Call up a nearby shop that has broaching capabilities and ask if they can help you out. Bake them some cookies along with a video of some competition footage. In five years of asking local machinists for help I've only been turned away once. They are very often happy to help - just be respectful and courteous and explain what your using them for.
Last year I called up a distributor and ask about getting a 1/2" hex broach for a reduced cost. Next thing you know they sent us one for free!! Use your power of communication and salesmanship, you'll be surprised!! |
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#29
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Re: Hex Broach Options?
Doug, you said it! I've not asked a lot, but I did get a shaft and some sprockets machined down for no charge. I think there are certain trades like machining and welding that, if you appreciate their art, will go way out of their way to help you. They guy who turned down out driveshafts one year proceeded to give me a 1/2 hour shop tour and offered to let us feed off their scrap metal pile as well. It never hurts to ask..politely!
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#30
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Re: Hex Broach Options?
I've been searching around some more for less expensive hex broaches and so far the least expensive I have found are the "Value" hex broaches at J&L:
http://catalogs.shoplocal.com/jlindu...genum ber=418 (see bottom of the page) Has anyone used these? They are significantly less expensive than Dumont anywhere but I am wondering about the quality. I am no stranger to cheap import tools and believe they have there place but I am wondering if these are just a waste of money or a good deal. I haven't had good luck with cheap import taps and dies but have found some of the import drill bits, end mills and collets to be of decent quality for my needs. Does anyone have any guidance on "value" broaches? |
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