Aircraft Tool Users and Collectors > Discussions About Classic Tools for Aircraft

Broaching (ha ha) a new topic

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johnsironsanctuary:
One way to approach the problem would be to find something that has that spline already cut. A trip to the local driveshaft repair shop might find a yolk with that spline. If I were making one, I would look into wire EDM. That would only require a cad drawing of the spline and paying for the machine time. No tooling. A wire EDM looks kinda like a band saw, but the wire has an electrical charge that removes metal by reverse welding metal from the part to make a kerf. Very precise!

leg17:

--- Quote from: johnsironsanctuary on October 31, 2017, 11:20:01 AM ---..... If I were making one, I would look into wire EDM. That would only require a cad drawing of the spline and paying for the machine time. No tooling. A wire EDM looks kinda like a band saw, but the wire has an electrical charge that removes metal by reverse welding metal from the part to make a kerf. Very precise!
--- End quote ---

Likely to cost $500, if you can find a shop sympathetic to interrupting for a one-off job.
And, since the wire goes all the way through, would the socket drive end have to be made separately and welded on?

Cutman:
Thanks all for the interesting contributions.  It's as I thought, doing 1 is expensive, doing 500 is cheap.

I wish I could find other folks that need it, but it's a pretty rare user anyway.

FWIW the fastener looks like a gear welded onto a stud.

I broke down and paid $140 for the appropriate socket from Kell-Strom.  Nasty cost but tit is a new socket so they probably ran some off recently.

Thanks again for all the info.

Best, Cutman

leg17:
Cutman
Thanks for the follow-up.
You made the right call.
The price factor will fade away with time and you will still have the best solution.

Nolatoolguy:

--- Quote from: Cutman on January 03, 2018, 12:20:25 PM ---Thanks all for the interesting contributions.  It's as I thought, doing 1 is expensive, doing 500 is cheap.

I wish I could find other folks that need it, but it's a pretty rare user anyway.

FWIW the fastener looks like a gear welded onto a stud.

I broke down and paid $140 for the appropriate socket from Kell-Strom.  Nasty cost but tit is a new socket so they probably ran some off recently.

Thanks again for all the info.

Best, Cutman

--- End quote ---

I would of guessed more for a specialty tool like that. It’s not cheap but no specialty Tool is.

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