Need Keway Broached

[lesrhorer]

Since no one wants to lend their broaches, and I can't find anyone locally who can handle metric broaching, I wonder if someone out there can broach a timing pulley for me? It needs a 4mm keyway. The hole diameter is 45mm.

 

[Suzuki4evr]

Would have helped with pleasure, but we have a distance problem

 

[Karl_T]

Do you own a mill or lathe? if so, there is a fairly simple way to cut that keyway with an HSS tool bit. I'll share more if you are interested.

 

[Suzuki4evr]

Do you own a lathe? if so, there is a fairly simple way to cut that keyway with an HSS tool bit. I'll share more if you are interested.

I was just about to suggest what you are about to propose. But you go for it.

 

[tjb]

Do you own a mill or lathe? if so, there is a fairly simple way to cut that keyway with an HSS tool bit. I'll share more if you are interested.

Not my post, but I'm interested.

 

[Karl_T]

Thought sure there was a tutorial on how to do this. My google foo is poor right now, best i found was this

CUTTING KEYWAYS IN A PULLEY!!!

Has anyone cut a keyway in a steel pulley without a broach? I was thinking about ways to do it, like using a blank cutter from a lathe and using a press taking small cuts or maybe a drill press in off position as a press taking small cuts. I have done one where the center of my tractor rear...

www.hobby-machinist.com

Basically, you got to get creative, somehow grind a piece of HSS to form of the slot, then use the carriage or quill to manually go back and forth as a poor man's slotter. Advance table or cross slide to depth.

 

[Jubil]

There are videos on you tube broaching on a lathe or mill.
Mr Pete, and Kieth Appleton to name a couple.
What machines do you have or access to? What material is pulley?
What does this pulley do? Pics would help too.
Chuck

 

[ErichKeane]

I'd have to build a tool for it, but I could do it on my shaper depending on the shape/vice-hold-ability of the pulley.

 

[Bi11Hudson]

Then there's always a couple or three hacksaw blades and a 3 square (triangular) file and a little elbow grease.

.

 

[Zack]

Yep, that's the way I broach. Tightly tape 3 good 32 tpi hacksaw blades together for an 1/8" broach in a pulley then dress it up/tweak it with a small triangle file. For a wider keyway just tape together more hacksaw blades. I've tried never tried to do a timing pulley though. That would complicate things.