I have two 6061 alum. hubs that have 1/4" keyway grooves in them. I need to widen the groove to 5/16". Is there anyway easy way to do this using a drill press? Other suggestions for a DIY solution?

Hope this gives you some direction.

http://www.keyseaters.com/stock_custom_keyseating.htm

It is HIGHLY NOT RECOMMENDED, but you could use a single or 2 axis machine table to attempt it.

http://www.kbctools.com/can/Navigation/NavPDF.cfm?PDFPage=453

Minuteman broach kit? Opening a 1/4" keyway to 5/16" in aluminum shouldn't be too difficult.

Dick Z

Thanks everyone.

OK, so I learned about broaches and actually found a 5/16C broach and 1 3/8 bushing for about $50. Now it seems I need a $$$ machine to use it? What type of manual machine is available to push the broach? Sorry for the newbie-type question.

try an arbor press. shouldn't be too hard to track one down to use.

.....Is there anyway easy way to do this using a drill press? Other suggestions for a DIY solution?

A 1/2inch drill press may be on the light side but a Mill/Drill will do the job.
Make an arbor and broach with the spindle locked.

Aluminum??

How about a hand file and a bench vise.


pix