I have a 1.25" bore gear hob, and a 1" bore horizontal milling arbor
for my milling machine.

I am trying to figure out how to make an adaptor. The ideal thing
would have an internal keyway and an external key, but I can't
off-hand think of a way to make that with sufficient guarantee of
concentricity.

The "Plan B" is a machined sleeve with holes for pegs which can engage
both keyways.

Not having ever used a horizontal milling arbor, should there be a
full-length key? Mine appears to only have one very short key.

-- 
atp
If you can't fix it, you don't own it.
http://www.ifixit.com/Manifesto

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