First, Thanks to all you guys for the valuable comments, I've learned
a lot. I've set up the hub on a milling attachment on the lathe
crossfeed and used a 3/4" boring bar with a 1/4" tool for the 1/4x1/4
keyway. I abandoned the process due to: 1) the extension on the
tailstock required that I reverse the hub to finish the back side (not
easy due to geometry), 2) the tool in the cast iron didn't "cut", but
more like scraped, really crummy cutting action (perhaps due to my
grinding the shape of the cutting tool, though that's not too likely).
I also found that there was a bit of rotational "slop" in the
tailstock, resulting in the boring bar turning slightly (perhaps
approx 5-10 mils). This process seem more like chewing a keyway than
cutting a keyway. Thus, I'm leaning towards buying a 1/4" broach on
Ebay ($10) and making a collar to fit the hub depth. Broaching the
keyway seems to be the more appropriate way of cutting this slot.
However, I'm still puzzled why some of you suggest that I can cut the
keyway on the shaper. Since I am an admitted dunce about shapers I
have several questions: 1) I assume that I need to buy / make a tool
holder that will accept a boring bar. I don't see how the standard
tool holder would work. 2) Then, there's the ram throw distance when
the ram is fully retracted and the vise. The vise is fixed on the
horizontal table, so I can't move it to gain more clearance between
the fully retracted ram position. I don't see how I could possibly
get sufficient ram travel - particularly with a boring bar mounted.
To make this work it appears to me that I would need to get at least
7" clearance between tool with the ram fully retracted and the back
side of the keyway.
Here's the reason I'm interested in answers to the above questions: It
appears to me that with a lathe and mill in my shop, that the shaper
is of marginal use and mostly redundant. Can any of you provide
reasons why a shop with a lathe and mill needs a shaper? (OK...
perhaps this is one of those quesitons that if I have to ask the
question, I shouldn't have the machine... but, I'm still trying to
figure out the shaper's purpose). Depending on your commnents I may
be leaning towards selling the shaper.
Again, thanks to all of you for providing advise, I'm very impressed
that you'all take time to offer advise to novice machine shop guys