Need Help!- Best way to modify pully and oldham joints....

[jevs]

My VMC had Fanuc DC servo motors on it. The old motors had tapered shafts, and rounded keys in the keyways. I am now going to use TECO AC Servo motors that have a 22mm straight shaft.

I want to know the best method to make the tapered holes in the oldhams and the Z axis cog pulley into keyed straight shaft holes.

The holes need to be for a 22mm straight shaft with a 6mm wide key that sticks up off the shaft 2.5mm. I also need to put a set screw in to hold to the key.

I do have a Lathe and Mini Mill currently to work with.

I was thinking to load them up in my lathe and cut the inside hole out close and then use a 22mm reamer mounted in the lathe drill chuck on the tail. I would then use a broach in my press to make the keyway. Then I would drill and tap the set screw hole.
The only thing bad about this method is that I don't have a broach or a 22mm reamer, and those tools will probobly cost me about $130 give or take.

Anyone have a better and/or cheaper idea or method??

Also what size set screw should I use, and is one set screw good enough?

Thanks,
John