keyway broaching: ram the broach in with the car?

my new e-bay buy, a 3/32nds keyway broach, will arrive soon. talk about excited ;-)

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3/32 A KEYWAY #22202 - eBay (item 160370977303 end time Oct-25-09

18:54:27 PDT)

still need the collar, of course. don't own a keyseater, or a shaper. or arbor press. or even a lathe, anymore, freakinDAHMIT. maybe I can ram the broach in with my truck? or lower the truck DOWN onto the broach, driving the broach through? I could use my rollaway 5 ton floor jack to lift it, so, what'aya think?

from my "of an equally astounding nature" department, comes THIS thing, which I really *do* think I'll probably end up using to push the broach through

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not sure how much force I'd -really- need to drive the broach through (say, mild steel)

using the tubing bender frame'll involve making some "bizarre upper welded adapter" first, but what the hell...the jack is 12 ton. jack probably won't work at ALL upside down. also "know to leak oil out its side" when turned sideways. this superb quality-infested jack can be removed from its red framework 'easily enough' though.

distance between top-center of jack (jack fully retracted) and top of (existing) red frame: 7.500 inches. broach has overall length of 5 inches.

I'd 'rather' have a stud hanging out the bottom 'pushing down' on the broach (just like a 'real' hydraulic press), but, ah jeeze maybe I can drive it upwards (more trickey to hold stuff straight and judge the alignment)

also have two *hugely* strong bessey clamps, and 'near tons' of scrap steelage...of all desripto's

here's a guy driving HIS broach with a cherrypicker cylinder

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- Broaching a keyway in a bead roller die blank

so alright, what ELSE can I use that's laying around here? lookin' for that eureka moment....

thanks guys

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Broaches are brittle, avoid side pressure. With a less than perfect press that means releasing all force frequently to let the broach realign with the ram.

The force should be within range of a 1 ton arbor press, or a good sized lead hammer if you are REALLY good at driving long thin nails straight.


Reply to
Jim Wilkins

Where do you live? Not the street address, since you use a .nu address it is unclear if you are stateside. If you are close to Michigan, send it to me and I'll broach it for you using your broach and my guide and press.


-- "Additionally as a security officer, I carry a gun to protect government officials but my life isn't worth protecting at home in their eyes." Dick Anthony Heller

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A couple of uprights out of square tubing with a section of channel welded across the top should do the trick. Drill holes in the square tubing every couple of inches to match the pins in the pipe bender so you can move it down as you go further and further through the hole. Also drill a hole through the middle of the channel for the broach to go through.

As someone else pointed out broaches are brittle so make sure you keep the pressure straight.

Enco has the collars/bushings for a decent price but be sure you get the right size for your broach. The portion of the broach that fits in the bushing can be a different size for a given keyway size. You may need shims too.

As for the tubing bender........ in case you don't already know it, it isn't a tubing bender. It's a pipe bender and there's a big difference. It'll do a decent job of bending schedule 40 pipe but it won't do tubing because they're sized different.

Tubing is normally sized by the OD but pipe is sized (roughly) by the ID. For example, you probably have a die that's labeled 1 1/4" but it's really going to be about 1 1/2" across it because 1 1/4" pipe has an ID of approximately 1 1/4" and the OD will be approximately 1 1/2". Unfortunately it won't be exactly 1 1/2" so you can't use it to bend 1 1/2" tubing. Make sense?

I, and many others based on posts I've read over the years found this out the hard way. :-)

Best Regards, Keith Marshall

"I'm not grown up enough to be so old!"

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DUMONT 3/32 A KEYWAY #22202 - eBay (item 160370977303 end time Oct-25-09

Reply to
Keith Marshall

The shop-built press is interesting, but here's another example of using a broach, with a more appropriate method

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Using the broach cutter without a cutting lube is going to cause unnecessary wear on the cutting edges.

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