Keyed Aluminum shaft

[AdamHeard]

Hi,
I'm trying to find 1/2" aluminum shaft with an 1/8" keyway. The problem is, so far only mcmaster has it at completely ridiculous prices. Anyone know a better place?

[AdamC]

Have you thought about making your own? It doesn't take an advanced milling machine to make a perfectly decent shaft. Getting a broach and a means to press is an easy way to make keyed shafts.

[AdamHeard]

Right now I need about 5 feet of it. That'd take a long time to make on a mill.

but...... what is the process for keying shaft on a press?

[Cory]

Originally Posted by AdamHeard

Right now I need about 5 feet of it. That'd take a long time to make on a mill.

but...... what is the process for keying shaft on a press?

There is none, as far as I'm aware.

[AdamC]

oy. For that kind of distance...I don't think you can. But if you're doing small lengths (<7") you can buy a broach, which is a serrated piece of metal that gets pressed across the surface of the shaft and cuts a keyway. By adding pieces of metal underneath the broach (we use sheet copper), you can increase the depth of the keyway. We made all our keyways on our prototype transmissions using a broach.

[chris31]

Originally Posted by AdamHeard

Right now I need about 5 feet of it. That'd take a long time to make on a mill.

Do you need one 5 foot piece? Or are you looking for more pieces that just total a length of 5 feet?

[EricH]

Originally Posted by AdamHeard

but...... what is the process for keying shaft on a press?

I wonder if Ed could tell you.

[AdamHeard]

Right now I need 4 pieces about 14-15" long.

[AdamHeard]

My mistake, I actually need 3/8" with 1/8" key. Makes it slightly less expensive on Mcmaster, but still more than I could stomach paying ($28 for 2 ft!!!!)

[sanddrag]

Originally Posted by AdamHeard

still more than I could stomach paying ($28 for 2 ft!!!!)

That really isn't all that bad when you consider it is 2024 (good stuff, stronger than 6061) and the time you'd spend machining in keyways.