Thanks for showing us how you made that Chisel Broach. Such a genius way to do it! No more welding silly bits of high carbon steel to rods etc. Thanks again!

@WinkysWorkshop

2 жыл бұрын

Yeah... i've done that too. This is for sure a better method.

As a machinist, I have used similar tools for many years. Actually learned about them from my dad. He called them a "Pecker tool", and so have I for as long as I can remember. Keep the vids coming.

@WinkysWorkshop

2 жыл бұрын

Thanks

Wow!!!! great presentation and very helpful to boot.....thanks so much, cheers from down in Florida, Paul

@WinkysWorkshop

2 жыл бұрын

You're very welcome! Thanks for watching.

I enjoy all of your videos I have learned a lot from you I just started machine work sense I retired a few years back

@WinkysWorkshop

2 жыл бұрын

That's awesome - THANKS!

Excellent video. As others have noted, broaching sets are the cat's pajamas but expensive for the home shop where the broaches won't see much use. An important reminder is that the power to the machine should be disconnected when doing stuff like this.

@WinkysWorkshop

2 жыл бұрын

Unplug the mill? Where is your sense of adventure? I'm kidding, maybe a good idea. Thanks for watching.

Good idea, I need to do this the next time I need and odd size. I have a Keyway broach kit. Not every size of bushing or broach. Great content. Thank you, Ed.

@WinkysWorkshop

2 жыл бұрын

Glad it was helpful!

Very good tool,Mark.Thank you.

@WinkysWorkshop

6 ай бұрын

Your welcome

You have just taught me something very useful, thank you.

@WinkysWorkshop

10 ай бұрын

Glad to hear that!

I have made similar devices to use on a lathe with a slotting attachment I also made, but the body is the same size as the shaft and I use a grub screw to push out the cutter after each stroke. It makes the keyway cutting repeatable with minimal setup but does require a new tool for each different shaft size and each key size.. I originally saw this in Model Engineer in a photo about about something else and thought that was a good idea. Please keep the videos coming they are all great.

@WinkysWorkshop

2 жыл бұрын

Interesting... and thanks for watching.

@EitriBrokkr

10 ай бұрын

That was my thought, that's similar to how rifle barrels were originally cut. Do you have a link to any thing showing a device like that?

This is a really good one Winky, as always, thanks. Move is done, but all the tools are still in pieces.

@WinkysWorkshop

2 жыл бұрын

You're very welcome!

Just a little bit of time and it saves from buying a speciality tool. Good job. I'm gonna make me one. Thanks 👍

@WinkysWorkshop

2 жыл бұрын

You're right, thanks for watching!

Thank you for sharing your ideas. I will definitely try this method to make shallow splines (8)on the change gears I intend to make for my lathe. With 9 of the original gears missing, I will have plenty of practice. Keep making the videos, as always a pleasure to watch them for many years ! 😊 Again many thanks from Scotland Regards Ritchie

@WinkysWorkshop

4 ай бұрын

Wow... nine gears is a lot, your arms will grow :o)

Good design, especially when broaching in a collet in a mill. For broaching a keyway in a lathe just clamp the cutter bit at a slight angle in the tool post and push the broach through the part with the carriage. The round holder won’t be needed.

@WinkysWorkshop

2 жыл бұрын

Thanks! Yeah... I've used a lathe a few times but it seems like the quill provides a lot more leverage.

Big thanks for sharing your knowledge!!! 🙏

@WinkysWorkshop

2 жыл бұрын

You're welcome. Thanks for watching!

I think that's a good idea , I've got a keyway to cut in a cast-iron pully . I haven't a broaching ,kit so I'll use your idea , thank you

@WinkysWorkshop

Жыл бұрын

For a "once in a while" key it's the way to go. Thanks for watching.

Gday Mark, great tool, very well explained, I’d say there’s going to be a few made now, thanks for sharing mate, cheers

@WinkysWorkshop

2 жыл бұрын

I'd say you are correct. And thanks! I hope all is well down under!

Brilliant design...I have really cobbled together some things in the past to do broaching operations, up to the point of even hammering a piece of square HSS through a round hole in aluminum ....

@WinkysWorkshop

2 жыл бұрын

Same here actually. Thanks for watching!

Nice video on the subject. As a home machinist I did a similar thing some time back and have used the tools several times over. Broaching sets are a big investment and may not be used enough to warrant the cost. (Not to mention metro and imperial required) it's definitely worth taking the time to make an individual tool as described in your video.

@WinkysWorkshop

2 жыл бұрын

Thanks for watching!! Agree.

Nice work Winky where there is a will, there is a way. Enjoyed the video , stay cool, cheers!

@WinkysWorkshop

2 жыл бұрын

Thanks, you too!

Good video it’s important to show people that there’s many ways to accomplish the same thing and you don’t necessarily need all the big tools to do it!!

@WinkysWorkshop

2 жыл бұрын

Thanks and I agree, I'm a hobby machinist and it's unrealistic to spend thousands on tools I'll use 5 or 6 times.

I was doing a 8mm blind keyway in a 25 mm bore on the slotter today. Similar tool but used 6mm square tool bit and side cut 1 mm either side. Used a 16mm round EN8 and milled the slot at 3 degrees. I mig welded the HSS at the end into the slot and ground the front rake cutting angle to 10 degrees. Drilled a 9mm hole for the tool to enter at the keyway end. Worked like a charm but your idea of the locking collar is brill.

@WinkysWorkshop

Жыл бұрын

Thanks for the comment. Good to know different methods.

I used to cut mine on a slotted but that was in a machine shop. If you can get a piece of round bar same size as bore put that in and work out where slot wants to be and drill a pilot hole you will find it easier and a little quicker. Just a suggestion.

@WinkysWorkshop

2 жыл бұрын

That would work. This method works easier in cast and aluminum but I didn't have any.

Great stuff, thank you, cheers from Florida, Paul

@WinkysWorkshop

2 жыл бұрын

Glad you enjoyed it

Thank you for your chisel broach. I had to make a new dipping die for my bead roller and it has a metric key way, of course but I can at least make the broach for the key way now.

@WinkysWorkshop

Жыл бұрын

Yeah... if i had to cut a bunch I'd have sore arms but its a good fall back method.

Thanks, very useful. I can see making one myself for a future project. Dave.

@WinkysWorkshop

2 жыл бұрын

Go for it! Thanks for watching.

I remember cut keyways using this method years ago, but I used an actual slotting tool made for the slotting head attachment on a Bridgeport. The tool I had was made by Brown and Sharpe. I'm sure that at one time, they made their own version of the slotting head too. Just reminiscing.

@WinkysWorkshop

2 жыл бұрын

I just looked up that slotting tool for the bridgeport. Very interesting. !!

If you have R8 or 5C sq collets, the tool steel cutters held in their corresponding size collet, can be used for the various diff sizes of keyways.....cheap or used R8 and 5C collets are readily available around $5-$7 ea....they are quick n easy to use in a pinch...the R8 and 5C sq collets also come in metric sizes if needed

@WinkysWorkshop

2 жыл бұрын

Good suggestion. There are many ways to do this. I have a set of ER but nothing that holds square stock.

Perfect timing Mr. Winky! Fabricating a drive pulley for a Fox Milling Machine-1912 + or - ?. I've been at with a hack saw. This will help beautify and clean up what I have started. Thanks!

@WinkysWorkshop

2 жыл бұрын

Thats great! I love the old machinery.

I'm the only old machinist who still uses a sine block and indicators on a granite inspection surface. Thanks for your video and all the best.

@WinkysWorkshop

2 жыл бұрын

Cool, thanks

Thanks again, I had to make a quill lock for my Busy Bee to keep the broach square, so that was another small project.

@WinkysWorkshop

2 жыл бұрын

Wonderful!

Great video. Thank you for sharing.

@WinkysWorkshop

2 жыл бұрын

Thanks

That is a slick idea. I needed a 5/32 broach and no one had one but the method you show may have been tough for my job. I have two sheaves on a Reeves drive on a Chinese Harbor Freight lathe. The keyways are just a touch off. When off the lathe they fit all the way into each other just fine, but with the sheaves on a shaft with a key, they won't slide all the way together and you lose power when the belt loosens up. I have to have them stacked to do it right and I don't think I could use this method through two of them....Jim

@WinkysWorkshop

2 жыл бұрын

I think in this case the depth of cut would be an issue.

Great info winky, keep'um coming..

@WinkysWorkshop

2 жыл бұрын

Thanks you sir

Always nice to learn new ways to do things. Last time I had to broach a keyway, I put the high speed steel in my tool post on my lathe. I had my part chucked up and moved the saddle back and forth to cut the key way. Moving the cross slide away from me to deepen the cut. Good idea for another video maybe? Thanks Winky!

@WinkysWorkshop

2 жыл бұрын

I've actually done the same and it works well but I has a had time getting enough leverage.

@dannywilsher4165

2 жыл бұрын

@@WinkysWorkshop Just curious, what position did you have your part in the chuck. I had mine where the keyway was at the three o'clock position and didn't notice leverage problems. Thinking back, it was on my 17 inch lathe, don't know if it created more leverage because of it's size.

@ellieprice363

2 жыл бұрын

@@WinkysWorkshop I can see where that would be a problem on a small lathe with a small hand wheel.

I finally got around to watching this video. Very cool! I need to make one ASAP!

@WinkysWorkshop

2 жыл бұрын

Thanks. Yes it is way better than buying a broach that gets used every few years.

@de-bodgery

2 жыл бұрын

@@WinkysWorkshop I lack broaches or the equipment needed to use them. I can do this on my drill press!

@WinkysWorkshop

2 жыл бұрын

@@de-bodgery I was the same until about a year ago when I inherited an arbor press from my former employer. I used to work at a printing plant and when they closed the doors my former boss gave it to me. It's much bigger than I need but very nice to have sometimes!

Good design thanks for sharing

@WinkysWorkshop

2 жыл бұрын

Thank you! Cheers!

Very neat little tool.

@WinkysWorkshop

2 жыл бұрын

Thanks

Some shops won't allow a wire wheel in the door because they're dangerous (put an eye out with a thrown wire). A ScotchBrite wheel does as good or better without the danger. I cut keyways on the lathe with the tool held sideways in a tool holder and the work clamped to a faceplate. It's tedious but it works and it's a lot easier to do that way than cranking my knee mill.

@Phantom-mk4kp

2 жыл бұрын

I've had wheel wire embedded 2mm into flesh using angle grinder cups. Never use anymore. Only need to forget eye protection once. Destroy them

@WinkysWorkshop

2 жыл бұрын

Interesting on the wire wheel. I've had them hit me before but never anything serious. I need to try the scotch bright wheels! Yeah... I knee mill without a quill would be hard to do. I've done this on a lathe and the quill was a little easier for me. I've also done this on a drill press with a mill table.

@TrippLilley

2 жыл бұрын

I never use wire wheels without putting on my leathers anymore. Otherwise I end up stabbed somewhere. Ferocious little porcupines.

@Phantom-mk4kp

2 жыл бұрын

@@WinkysWorkshop yes, no exaggeration I was cleaning rust off a steel garage door had 2 or 3 pass through a thin T shirt, had to pull them out. Just calculated they are travelling about 150 mph

@WinkysWorkshop

2 жыл бұрын

@@Phantom-mk4kp I'm sure it happens.

Thank you ! Some day this might get me out of a bind

@WinkysWorkshop

2 жыл бұрын

Yes, its a good way for an occasional keyway. Thanks for watching!

In all my 60+ years in engineering I have only ever cut a keyway one time only with a dedicated broach and arbor press, and that was when I was an apprentice because that is how we did it back then......but for many years since I've cut keyways by cranking the lathe saddle with a boring bar and 90 deg tool bit.,,,,...,for the occasional keyway the lathe/boring bar set-up is the most practical application and certainly the cheapest as you can grind a square HSS tool bit to suit the size of the keyway be it Imperial or Metric.

@WinkysWorkshop

2 жыл бұрын

I agree and I have done this in the past. For me the mill was easier because the quill on my mill has a better mechanical advantage. I'm sure some lathes are geared differently.

Great video, thanks for sharing

@WinkysWorkshop

2 жыл бұрын

Thanks for watching!

Thats great Mark i think i will try to make one, if one rounded the other end of the cutting bit it would set more solid in its holder i think.

@WinkysWorkshop

2 жыл бұрын

That may be true.

Way to go Winky. Requires a lot of elbow grease but well worth doing if you seldom ever cut keyways.

@WinkysWorkshop

2 жыл бұрын

Thanks Harould. It's really not as hard as you might think especially in cast iron or aluminum.

I think it is a darn good idea . It will for sure help me out making one . I just finished rebuilding my milling machine and since i am not making a lot of key ways , your idea will suit me just nice . Thanks for sharing ..... You don't happen to have info on a 9 inch South Bend . I need to know what change gears it should have and what size and pitch the lead screw should have . I am trying to help a friend to get it up and running .

@WinkysWorkshop

2 жыл бұрын

Thanks. Hey, there is a 9" South Bend Lathe facebook group with a lot of people (about 5,000). Good recourse! I have a quick change so don't know about the change gears on the 9"

ripper ! thanks for that - Got todays project sorted out :)

@WinkysWorkshop

2 жыл бұрын

Cool!

Nice job Winky.. Chisel broach. I like it Don

@WinkysWorkshop

2 жыл бұрын

Thanks Don!

Hey , I like that ! great idea as some of us don't do allot of keyways .. ENJOYED

@WinkysWorkshop

2 жыл бұрын

Yes, that's is me. Thanks

@shawnmrfixitlee6478

2 жыл бұрын

@@WinkysWorkshop me to , i do not use one much but this makes it easy..

Home made vertical planer right there, super adaptable brain you have...

@WinkysWorkshop

2 жыл бұрын

Thanks... yep, just like a planer

Thank you will be handy when needed.

@WinkysWorkshop

2 жыл бұрын

Thanks... yes, much cheaper then a broach and bushing (s)

Thanks for the video!

@WinkysWorkshop

2 жыл бұрын

You bet!

Thank you. Very nice idea. Might be slow but way cheaper than a real broach.

@WinkysWorkshop

Жыл бұрын

Very true, your welcome!

Hi Mark, i want to try to make your tool: in my milling machine i don't try to make many verticals cuts! But i will try! Usually i make a small hole, out of center, with the OD= width of the spline,after i make the central hole shaft, so i have to cut only the round corners to have the seat of the spline, this work if you start from zero, if you just have the central hole, your method Is great! Thanks for share, Alberto.

@WinkysWorkshop

2 жыл бұрын

I've thought about doing the same although with cast iron and aluminum the keyway cuts easy. The mild steel I used in the video required more time and effort. I would not want to do this all the time but if you only need to cut an occasional keyway it's great.

Great video

@WinkysWorkshop

11 ай бұрын

Thanks!

Very slick tool much better than a file.

@WinkysWorkshop

2 жыл бұрын

For sure a file would be a hard way to go! Thanks for watching.

Hi Mark. Today I was asked to enlarge a bore in a ‘drive dog’ and add a key slot. Umm I thought, I have no broaches, what could I do. Thankfully you have given me a great idea what I can do. Thank you. 👏👏👍😀

@WinkysWorkshop

6 ай бұрын

Thanks great!

Nice job Mark

@WinkysWorkshop

2 жыл бұрын

Thanks 👍

You always make me think Winky! (Thanks!!!) What are the disadvantages of drilling a hole as a key-way and using round stock as the key where that is a practical alternative (ie. both shaft and pulley are the same material)?

@WinkysWorkshop

2 жыл бұрын

I've used the round rod keyway several times. I suspect the only disadvantage is strength but for lot torque they work well.

Obrigado amigo! Muito bom!

@WinkysWorkshop

Жыл бұрын

You're welcome.

That's more or less how I have been doing it but on my Lathe, I use my boring bar with the cutter side ways, works fine...

@WinkysWorkshop

2 жыл бұрын

True, there are many ways to do this. I had some problems doing it on the lathe due to leverage. It worked but it took a little more effort.

Nice tip

@WinkysWorkshop

2 жыл бұрын

Thanks!

I like it! (Followed by a little dance)

@WinkysWorkshop

2 жыл бұрын

Cool!!! Thanks! Ha

Nice work. Well done. In the beginning You say that chissel(?) broach is economical. Ehhh. I checked prices not long ago. Here (Sweden) the broach cost more than 60 USD without the needed "inserts".... They also cost... Your simple, quickly made and effective tool looks like the obvious way to go.

@ellieprice363

2 жыл бұрын

Yes unless you have a lot of different size long keyways to cut in many parts on a regular basis. Then a commercial broach set would be more economical.

@WinkysWorkshop

2 жыл бұрын

I agree, it just doesn't make sense to buy expensive tooling that will be used once every year or two.

@WinkysWorkshop

2 жыл бұрын

Exactly... my shop is basically a hobby machine shop so buying a broach doesn't seem like the best option.

@Stefan_Boerjesson

2 жыл бұрын

@@WinkysWorkshop When the day comes I need to do that work, Your design is the alternative. I've got a pedestal grinder (standing on the floor) but not grinded any HSS yet....

THANKS WINKY

@WinkysWorkshop

2 жыл бұрын

Your welcome!

buen video amigo

@WinkysWorkshop

Жыл бұрын

Thanks

Great video as always! How did you lock the spindle on your Mill?

@ellieprice363

2 жыл бұрын

Low speed in low gear is pretty effective but the spindle can also be locked with the brake lever cam.

@mgardnerflipflopmachinist

2 жыл бұрын

@@ellieprice363 Mark has a round column mill, there is no brake lever like a Bridgeport. On my enco round column mill, low speed on the pulley will still cause the spindle to walk back and forth. Just curious.

@ellieprice363

2 жыл бұрын

@@mgardnerflipflopmachinist Sounds like you’ll have to figure some way to wedge that low speed pulley to keep it from rocking.

@WinkysWorkshop

2 жыл бұрын

I didn't

@WinkysWorkshop

2 жыл бұрын

In the past I locked the drive pulley by clamping a piece of wood to it but it really isn't necessary. If you have no side relief on the cutter it stays straight after a couple cuts

Hey Winky. What DRO is on your mill? You may recall we spoke at Flywheelers and we determined my mill is nearly identical to yours. I am looking at getting one. Is that magnetic or glass pickups?

@WinkysWorkshop

2 жыл бұрын

My DRO's are as cheap as I could find. The depth DRO has an auto shut off and the battery last about 2 years but the X and Y do not and if I forget and leave them on they only last a couple month. They all work perfectly although I had to replace the X axis after about a year. I suspect coolant made it fail.

What you are effectively making is a graver. To avoid diving into the work, you can grind a heel on the underside to give the tool something to ride on. Lots of stuff on the ‘net on shaping gravers.

@WinkysWorkshop

2 жыл бұрын

Thanks for the tips! I've never heard the term before. I'm sure there is a more ideal shape.

@bradthayer6782

2 жыл бұрын

@@WinkysWorkshop there is a rich field of work in engraving, and a combination of art/science in the shaping of gravers.

@WinkysWorkshop

2 жыл бұрын

@@bradthayer6782 Ahh... I understand now.

How many times would one be able to carve out keyways with non heat treated steels before it gets too round?

@WinkysWorkshop

2 жыл бұрын

Honestly I touch up the HSS after one key way cut in steel but cast iron and aluminum the cutter stays sharp a long time.

If you use a smaller end I’ll to remove the bulk of the material and clean/square the key up with the broach it save some effort.

@WinkysWorkshop

2 жыл бұрын

Thats true. Cast is easy but on steel this might help a lot.

A great way to make a simple single point chisel broach. The only bit I'm not grasping is why don't you specify an angle for the slope of the slot in the housing?

@WinkysWorkshop

2 жыл бұрын

The slope was to provide clearance in the hole for the rod that holds the HSS but you may be correct that the slop was not needed (or at least less of a slope) but the HSS would need to be much longer to cut deep enough or the locking collar would need a keyway cut in it.

👍👍😎👍👍

@WinkysWorkshop

2 жыл бұрын

Thanks

salut ces une bon idée merci

@WinkysWorkshop

Жыл бұрын

You are welcome!

All by hand? How long did it take you? Wonder if this would work well on cnc type?

@WinkysWorkshop

2 жыл бұрын

It tool maybe 4 or 5 minutes. After making this video I found out that Bridgeport made an attachment to do the same. It was either motorized or ran off the drive.

thanks winky

@WinkysWorkshop

Жыл бұрын

For sure, thanks for watching

I have a small benchtop metal planer with an attachment for doing internal keyways. I think what you made there might work better than the attachment I have. Mines just a rod but a square hole 90⁰ to the rod in the end for a tiny piece of HSS. I'm going to try your method. Check out the only video on my channel about my planer I restored. Thanks for sharing Winky.

@WinkysWorkshop

2 жыл бұрын

It's hard to say what would work best. That is a VERY COOL planer you have. The gear change for changing the direction is wild. Seems like it would be prone to wear but I guess it must work well. I love the old planers but don't have the space for another machine.

@onestopfabshop3224

2 жыл бұрын

@@WinkysWorkshop Thanks for checking it out. Take care.

@ronkellis769

2 жыл бұрын

I also thought shaper tool. Something else to try.

@WinkysWorkshop

2 жыл бұрын

@@ronkellis769 I've seen shapers but I'm not very familiar with the way the tools are ground. I'm sure they may be ideal for this process.

thanks.

@WinkysWorkshop

2 жыл бұрын

Thank you for watching!

Wow! You weren’t kidding when you said your broach is labor intensive. I made the broach and after several hours I finished with a key set. It’s not pretty but it’s functional for what I’m using it for. How do you lock the from turning on a bridge port? You made that comment and it’s imparitive that it’s locked. TNX Frank

@WinkysWorkshop

11 ай бұрын

I guess it depends on what the pulley is made out of. I have done this with aluminum and cast iron and it seems to work ok. I never lock the spindle. One started it seems to self align.

@frankpiazza953

11 ай бұрын

@@WinkysWorkshop I noticed mine was self aligning as well after I got a the slot started. I at least have a new tool now. I cut a 1/4 inch key and I was wondering if it would have been easier to grind the HSS cutter on a slight angle while I was grinding the 15 degree angle? Thanks for the tip. Koeep up the great work. God bless. Frank

@WinkysWorkshop

11 ай бұрын

@@frankpiazza953 I tried a couple angles. It's definitely a balancing act. Too much angle and it will try to cut deep but it there is no angle it tends to slide and not cut. Just experiment and see what works best.

@frankpiazza953

11 ай бұрын

@@WinkysWorkshop I remember that you said that in the video, but I was referring to an angle perpendicular to the angle you are referring to; in other words if you angle the cutter right or left as you grind the 15 degree angle. Wow thanks for the quick reply’s all in the same days. BTW I’m trying to understand speeds and feeds in the reference manuals, and how SFM is measured and translated into numbers usable at the lathe or mill. Would be nice to watch a video explaining that. Now I’m going to make a few chips. God bless. Frank

@WinkysWorkshop

11 ай бұрын

@@frankpiazza953 Thanks for the input. I need to do a speed and feed video! It would be a learning experience for me as well. I think I'll make a chart for brass aluminum and mild steel and convert to RPM. (eliminate the daily math!)

I know this has nothing to do with this video but l have gotten a 3 jaw chuck that the back plate was turned 0.0110 to small. Can l braze it up and return it to the right size

@WinkysWorkshop

2 жыл бұрын

Maybe there is a type of locktite that would fill the gap. Maybe people use an undersized plate so that they can adjust center.

How d'ya keep the spindle from turning?

@WinkysWorkshop

11 ай бұрын

Once you make a couple cuts the tool seems to follow the existing groove. The first time I tried this I clamped a bar to the pulley but it's really not needed.

How did you keep the spindle from turning?

@WinkysWorkshop

2 жыл бұрын

The first time I used this type took I clamped a piece of wood to top pulley but I found there is no need. Once the cut is started it continues straight because the cotter has no side relief.

Wait, so if you want to grind a 65° angle you'd have to measure 25°, not 20°. So what is it now?

@WinkysWorkshop

2 жыл бұрын

Don't ask me... I just read the protractor. It's from vertical or horizontal but maybe I looked at the protractor wrong. The graphics I inserted make more sense to me.

Ugh! Broaches! I *hate* those things. They would cut tapered keyways….

@WinkysWorkshop

2 жыл бұрын

I've never had a set but I have used them. Mostly this is way cheaper! Thanks for watching!

You might like to consider renaming your video. Personally I'm not interested in toolmaking, only tool use and technique.

@WinkysWorkshop

2 жыл бұрын

What would be a good name?

@arkadybron1994

2 жыл бұрын

@@WinkysWorkshop I would go with, "Making a tool, to cut a keyway without a broach."

@WinkysWorkshop

2 жыл бұрын

@@arkadybron1994 - Yeah... you are right, that would have been better. Thanks

Awesome! Thanks for sharing!

@WinkysWorkshop

2 жыл бұрын

Thanks for watching!