pic: 816's 2011 Off-Season Teaser

[thefro526]

Originally Posted by Cory

I can tell you from our experience that would likely be a problem and require it to be broached multiple times, or from both sides (with a standard push broach). It's going to take a LOT of force too, since you have so much tooth engagement.

Just wanted to Follow up on Cory's post in case someone stumbles onto this thread in the future.

Each part, especially the hubs, did need to be broached multiple times. We've found that most Aluminum Hex runs a few thousandths over, which was enough to make assembly a PITA. If I counted correctly, each sprocket has now had the broach pressed through it three times, once to do the primary cut, two more (each from a different side) to open the hex up enough that it plays well with hex shaft. The wheels each took between 3 and 4 passes a piece before they played nice, again alternating sides with each pass.

With any luck, this should be running tonight.