Didn't think about the 1/8" wall thickness.  Hmm.  Maybe a series of
interrupted thru cuts in a line to use multiple shorter (lengthwise) keys?
Sort of like multiple woodruff keys that are sometimes used on wide gears.
But full depth through the shell?

I don't think Marks suggestion of cutting all the way through end to end
will work.  The key is no longer in shear and will want to rock over.

Hmm. Sounds like a proper arbor is the easiest way:P  What taper are you
looking for?  Maybe post a WTB over on PM.


On Thu, Jan 3, 2013 at 9:13 AM, andy pugh <[email protected]> wrote:

> On 3 January 2013 14:04, Stephen Dubovsky <[email protected]> wrote:
> > Turn/bore a sleeve.  Very concentric.  Cut a slot on the OD using endmill
> > or wodruff keyway cutter.  Use broach or shaper to cut internal keyway
> (and
> > not directly under the outer keyway;))
>
> There is only 1/4" diameter difference, so the wall thickness of the
> sleeve may not be enough for the outer keyway.
>
> (I am hoping that an arbor of the correct diameter and taper will turn
> up on eBay)
>
> --
> atp
> If you can't fix it, you don't own it.
> http://www.ifixit.com/Manifesto
>
>
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