square hole?

[55 dude]

hello everyone!, new guy here and i have a question or 2 about a shaft i need to make or have made. it is a 2" dia shaft for a mixer/grinder (sausage) i have enclosed some pic's of it to help everyone in their responses. it is just shy of 6" long and square hole in the end of shaft is 1" square x .838 deep. how much work is involved in making this square or should i cut off end and weld on splined shaft. the grinder is 7.5 hp (1750 rpm) through a gearbox with 9-1 reduction ratio. the shaft is driven by a 96 tooth #40 roller chain, very low rpm as it drives mixer paddle shaft. thanks

[Mcgyver]

lots of ways to make a square hole, but in this size and it being blind, I'd fabricate. weld up the internal square shape then turn the outside. your call on which is less work, spline probably if you've got it. probably could take say 2" dia, mill a 1" slot and weld a cap then turn

[307startup]

Assuming you have lathe and mill....Centerdrill the middle hole and progressively drill to depth and size using drill bits up to about 3/4 inch (unless you have a 7/8 or 15/16 drill) then then mount 1 in. end mill in tailstock and go to depth using 1/16 pecks (or use boring bar). Scribe straight lines at 90* intervals around perimeter of hole. Mount in vise on drill press or mill and centerdrill (smallest reasonable size you have or can beg, borrow or steal) without drilling past smallest diameter (no shoulder or chamfer) at center of intersecting lines at corners. Drill to depth using 1/16 or 3/32 drill bit. Mount 1/8 or 1/4 end mill and run cutter parallel to your lines without going past intersecting lines. Make progressive passes to width and depth. After running all four edges, use small file to dress corners. I'm also assuming the square shaft has a slight chamfer and blended edges at shank. This should work for you as I have done this several times in the past at work. Happy project!

[55 dude]

wow! thanks for the quick response guys. anyone else? all feedback is welcomed. i will post pic's of rinished project.