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Discussion Starter #1
Ok so I showed how I make Hex recesses using a 'rotary broach' which I also showed being made. http://www.mvagusta.net/forum/showthread.php?t=48542
This tool has it's limitations though...as 'broaching' anything above 5.5-6mm hex puts a lot of 'load' on the lead screw/ rack and head bearing of the reasonably small engineering lathe I have. Therefore I have developed a 2nd technique which is very effective (in fact I use this technique most!)..although it too has it's limitations (due to the opening capacity of the vice jaws).....in which case you could use a small 'press'.
It involves making 'broaches' in a similar way to the last but using sections (50mm) of 10 & 8mm allen keys. And some re-machined brass plumbing 'stop ends'..from your local hardware (home depot...B&Q..etc).
As before the 'broaches' are 'dished' ...machined and 'tapered' to achieve the 'end' being 3% larger than the required 'hex'...eg 5mm hex needs a 'broach' 5.15.......6mm hex needs a 6.15 broach.
A corresponding hole (again 3% larger) is bored into the work piece...then 'chamfered'.
The 'broach' with it's 'machined' plumbing fitting (removal tool) together with the 'workpiece' are then 'pressed' together in a sturdy vice. The end of the 'broach' is then held between the jaws of the vice and two spanners used in opposite directions on the 'brass removal tool' and the task is complete.
Below are some shots of the manufacture of this system..it's operation in creating an 8mm 'hex'...and my 'box of tricks' ..all home made for this process which I hope clarifies the process.
Oh, and Dick (racasey) it's not suitable for broaching in stainless steel..I tried it today.
Cheers for now
Brian.:)
 

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Discussion Starter #3
......and people say I'm a magician......beautiful work as always mate:mouthwate
Cheers Chris.... I'm not great with 'card tricks'...but I can make large chunks of metal 'disappear!':laughing: (a lot of them into the bin)
Thanks mate
Brian.
 

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I thought you said this one will be the simple method, great, now I'm more confused. Good job Brian. And Crutchlow almost got there !!!
Cheers mate!....If I can think of a 3rd way I'll make it the simple one!.
Glad you liked it...
Cheers Brian:).
 

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Wow, that's great! How long do the broaches last?
Thanks...,they hold up pretty good Spry..and it largely depends on the 'material' your'e broaching. As I mainly work in 'non-ferrous' metals they last well...and being cheap to buy the allen key sets are easily replaced:)
Good way of broaching eh??... Thought you'd like it.
Cheers
Brian.
 

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Thanks...,they hold up pretty good Spry..and it largely depends on the 'material' your'e broaching. As I mainly work in 'non-ferrous' metals they last well...and being cheap to buy the allen key sets are easily replaced:)
Good way of broaching eh??... Thought you'd like it.
Cheers
Brian.
Yeah, I'm actually quite tempted to try that. It looks a bit easier than the other machining you have posted about.
 

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Cheers Chris.... I'm not great with 'card tricks'...but I can make large chunks of metal 'disappear!':laughing: (a lot of them into the bin)
Thanks mate
Brian.
I'm not a magician either Brian but got the nickname 'Magic' from my pool/9 ball buddies :smoking:
 

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Discussion Starter #11
this one i understand lol
Ahhhhh.... the IQ effect from Mr anonymous Brusta is bearing fruit:yo:lol

Cheers mate...the beauty about it is Carlos.. is that the 'stuff' you need for it is cheap and readily available in your local hardware store...and it works ...well!
Brian.:)
 

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Brilliant. It took me a few passes through the photos to see what you were doing, but it's 'just' a press/shearing action that carves the flats, yes? Very cool.

You should have your own sub-forum around here.
 

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Brilliant. It took me a few passes through the photos to see what you were doing, but it's 'just' a press/shearing action that carves the flats, yes? Very cool.

You should have your own sub-forum around here.
Thanks Chris glad you liked it.....:)
I've sent you a PM

Oh and re the 'Sub-forum' thing....I'm scared of anybody getting offended or causing 'controversy'.......there's been enough of that lately:laughing:
Brian:laughing:.
 
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