Three Ways To Cut Keyways! No special tools!

This episode on Blondihacks, I’m showing three ways to cut key ways! Exclusive videos, drawings, models & plans available on Patreon!
/ quinndunki
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[@samson5158]

Glad to see you broaching this subject.

[@timnell207]

Booooo. Lol

[@WatchmakerErik]

Take my upvote and leave.

[@Anonymouspock]

she makes many key points in this video

[@michaelstump6933]

This video is way groovy.

[@KathrynLiz1]

Not a bit boring..

[@kevinpulver4027]

And here I am 7 months later for a refresher course. My 16-year-old son needs a key way on a generator pulley on a 49 Plymouth.This will be life changing for him!

[@scotthutson736]

I did something similar in 1991 while underway on a submarine in the Atlantic (we had to repair a large pump and needed to manufacture a part). We did not have any fancy broaches but we did have an old South Bend lathe. I ground down an old style boring tool to make the cutter. It took a minute to cut the keyway but it worked just as well. Nice tips, Quinn.

[@VladekR]

was that pump for pumping reactor cooling heavy water? 😂

[@aaronclair4489]

That's a super cool story. I wasn't aware that a submarine would carry a lathe. I'm surprised you had the space for it, and obviously there would be noise/vibration concerns. Out of curiosity, what sort of machining and repair capability did you have? Mill? Welders?

[@jasongreene303]

@@aaronclair4489 I think you'll find that most ships and subs have a well tooled machine shop on board.

[@pieterveenders9793]

@@jasongreene303 I know it's not uncommon for very big ships like oil tankers, container ships and aircraft carriers to have at least a lathe and welder on board, if not more. And I can also see how more moderately sized ships, such as cruisers and destroyers probably have such machinery and equipment on board as well. But a submarine?! No way there's room for a lathe on anything but a nuclear submarine and maybe some of the ultra-large diesel-electrics. On top of that the entire name of the game in military submarines is to remain stealthy and silent, running a lathe on board of one must surely give your position away to any other hostile submarines in the area?

[@bknesheim]

@@pieterveenders9793 I do not know what equipment you find on a US sub, but I do know that they often do things aboard that make a lot of noise. They just do not do it when there is a need for stealth. You can also mechanical separate machinery from the hull and reduce a the noise transmitted to the ocean.

[@PoignantPirate]

I just want to say that I appreciate you putting in the extra effort to fully demonstrate broaching on a scrap part so you can show the result of the first pass. That dedication to a good educational comparison is part of why I love your channel.

[@petetheprettygooddog]

Quinn, From an engineer and machinist, you know your stuff. Well presented too. Good job.

[@trackie1957]

I agree. She is also self deprecating in a humorous way that makes her presentation more approachable.

[@charlesmauro5905]

Engineer and Machinist! 👍 I've always said that anyone that wants to be an engineer, needs to spend time in a machine shop. Countless times I've argued with engineers that had no concept of what it takes to manufacture some of their ideas that they so easily put on paper without understanding what it takes to fabricate them. Only once in my almost 50 years in the trade, did I work for a company that wasn't a Job shop. They had their own product which they designed and manufactured. It makes it so much easier when the Engineer and the Machinist work side by side to solve any problems they have as it occurs, when manufacturing a new product.

[@Ternaz88]

@@charlesmauro5905 I couldn’t agree more with that sentiment. It’s all too unfortunate the amount of “engineers” that can’t/don’t understand that while the things they’ve learned in school are best practices, in real life things don’t actually behave exactly like they do in solidworks.. I had a recent graduate of an engineering program ask a fellow experienced engineer what O.D. and I.D. meant…. It should be mandatory in order to complete your program and get your degree that there’s a certain amount of hours you need to work in a shop, preferably a shop that’s applicable to they type of engineering you want to do. I’m in the states so maybe requirements like exist elsewhere.

[@BruceBoschek]

@@charlesmauro5905 I got my PhD in biological cybernetics, but while doing my dissertation work I did an apprenticeship in the machine shop of the Max-Planck Institute, beginning with make a square block within tolerances from a chunk of steel using nothing but a file. Throughout my career that training helped me when I wanted a specialist machine or tool made. I could either make it myself or intelligently explain and/or draw my requirements for the machinist. Secretly, I wish I had become a machinist, in spite of having had a successful career in science.

[@michaelwest4325]

As always kudos for showing alternate methods and work around from the expensive specialty tool. One of many reasons your content has such value!

[@mcsmith82]

Every Sunday morning (Australian time), your videos make me 18% less sad!

[@jackdawg4579]

cheers for this video Quin, I was aware of the methods for cutting a keyway on a lathe or mill, but it was really good to see it explained in terms simple enough for me to understand and have it demonstrated so I can follow along!

[@johndufford5561]

I've zero interest in making a steam engine, but I love the things you are teaching me while you make one. Same thing here: always wondered how one could cut a slot (in this case, a keyway) on a machine that spins material! My lathe is so much more capable than I am, but you're teaching me to THINK. Very grateful for that, Quinn. Press on!

[@mikebaudrexl9897]

Thank you for sharing your experience, knowledge, humor and skill with such calm and accurate commentary. Great job!

[@martinolesen9930]

As always, short and clear, i really respect your knowledge and craftmanship, thank you very much 😀

[@LesNewell]

I have found that if you use carbide when doing the mill/lathe trick you have to retract the cutter before returning, otherwise the cutting edge chips. HSS seems to handle dragging on the return stroke much better.

[@TrevorDennis100]

A good tip Les. Thanks.

[@mpetersen6]

I'm surprised carbide will handle the load. Another reason not to use carbide in a regular shaper. Dragging the tool back across on the return stroke will damage the tip. A hydraulically powered shaper on the other hand automatically moves the tool out of the way. On gear shapers the work retracts out of the way.

[@clivehaynes2183]

@@mpetersen6 It's been many years since I used a shaper but the old geared one's that I used back then all had clapper boxes which prevented the tool dragging on the return.

[@DeanTheDoctor]

@@clivehaynes2183 Neat! 😊🌎✨

[@robertrussell2595]

Your voice delivery and correct terminology use is flawless! Perfect video quality. Thanks also for presenting the cutting audio from broach or cutter passes...it is the sound of Victory!!!

[@howardosborne8647]

Great video content and I applaud you for warning users of long keyway broaches to frequently release the ram pressure from the top of the broach to prevent accidental breakage. We were taught to always relieve the ram pressure every couple of teeth of broach travel.

[@pauljcampbell2997]

As a newby to this engineering & lathe type stuff, I found this really helpful. Thank you!

[@seabirdsailing6401]

Brings back memories, I have used all 3 you're methodes .Your'e guidance is good, I was a tool and die maker for 40 + years

[@abefroman5191]

I'm so glad I found you. How thorough but straight to the point. Thank you

[@SethKotta]

You can also use a file. It might be more labor intensive, but after after a week or so you'll be halfway there!

[@howardosborne8647]

I can feel the callouses and blisters just thinking about it😂😂

[@AttilaAsztalos]

I should have learned by now that every time a machinist says "no special tools needed" what they actually mean is "beside a fully equipped workshop"...

[@spacecaptainscott]

@@AttilaAsztalos Yes, and then pulls out the special tool kit!

[@lordchickenhawk]

I have done this when fitting "in the field" It's actually not too slow if you do some "priming cuts" with a hacksaw. (provided you don't have too large a hub diameter to be accommodated by the saw frame.) Getting the corners of the keyway sharp is possible if you grind an emergency "safety edge" onto one side of your file with your angle grinder.

[@patricksmith4424]

Yes I agree, she is stool using an expensive milling machine for the alternative.

[@puzzlefactorysoundstudios]

Ahh, that was BRILLIANT! Thanks Quinn. My 3yo daughter and I love watching your videos.

[@ralfzaeper2035]

I am working on a workmanship program in our company and crossed ways with your channel. I am VERY impressed about the depth and effectiveness of your teaching. doing metal works for 30 years I find all essentials and more covered and super well explained.

[@FullSteamDesigns]

Those are some great tips to keep in the back of my head. When I first got started in this stuff, I worked at a machine shop mostly doing operator stuff. They got a job that required a ton of keyways. They went out and bought a vintage keyway machine and had it refreshed by the company. I can't remember how many I ended up cutting. It must have been in the thousands.

[@paulkinzer7661]

I really appreciate your idea of what 'expensive' is. So many sites/channels I visit have a much different definition. I watch/read for some time, and then find out that this great part/accessory/thing I'm finding out about will cost more than I spent on the machine I'll be using it in. Or the tool I need to make the thing costs far more than just buying the part, or dozens of them. It's true that, sometimes, that's okay, since making the part is the goal, but getting these great tips is so helpful, because I have very little cash to spare!

[@cobrajet8866]

You earned me right away - New Sub - ME with a machinist heart. Great verbal communication skills. You explained every detail.

[@jamesdekeyser6503]

As usual, again a very clear and usefull video. I already learned so much from your YT video's. Especially at my early days as a hobby machinist.

[@Jim-fe2xz]

The true test of knowledge is one's ability to share it in a clear and simple way! Thank you for sharing your knowledge! I love your humor "for the vitamins, kitty hair, because we're civilized". Priceless! This very old guy appreciates it very much!

[@mikehart6708]

You are a good teacher........a vastly under rated skill. Thank you for this lesson

[@stevepurcell7266]

Amazing problem solving tech. Blondi explains every step very well.😊

[@bobbyshaftoe]

Chamfers are what separate us from the animals! = Instant SUBSCRIBE button right there!

[@slakjawnotsayin5451]

What an awesome series! Thank you for doing all of this for us!

[@clemm17]

I like your comment on the lathe. An old machinist told me the biggest limit of what a lathe can do is the operators imagination.

[@KimbrellBrad]

Great techniques! I have wanted one of those sets but now see that for the limited number of keyways that I cut I can make a tool and use my mill. So many things I have learned about machining have come from watching and talking to other machinists. Thanks for the tips!

[@cana125dh7322]

I find your videos both informative and soothing. God Bless.

[@Clough42]

Thank you for showing the surface finish on that part. I turned the first round 4-jaw challenge parts on Stan's Logan lathe this weekend and got similar results, which made me sad as well. Emery is the only thing that saved me.

[@beserkergang]

You have impeccable timing! I needed this very thing today.

[@clydedecker765]

As a testimonial to your teaching skills, I had actually guessed the three methods you were going to demonstrate before you actually revealed them from information contained in your previous videos. Thanks again, Quinn, for your fine skills as an instructor.

[@michaelcurl2440]

Quinn - Thank you for continuing to provide excellent content! Mike

[@reaper060670]

This is a brilliant video. Only just found ur channel. I love this stuff. I'm learning new things all the time thanks to great ppl like your good self.

[@todddrumheller6726]

I love your knowledge, tips and humor. Thanks for taking the time to create such great videos for our enjoyment.

[@dwhallon21]

Watched this one from start to finish. First way was most common to me, ways 2 and 3 work good as well. Loved it

[@garyhardman8369]

Great tip for us financially challenged people. Thank you so much Quinn!

[@theperl9663]

Was great, as usual, I always learn something. It's good to see someone else turning the handles, so I can catch my mistakes.

[@brucematthews6417]

Another great video! I've used the slotting tool for keyways and a variety of shapes over the years in both my mill and lathe. My own success was a match for yours. It's a great method for the home shop. One of those was a 60 degree angle push cutter to "hex" out a 9/16 hole to fit over a 14mm hex. This means only forming 6 corners with some short arcs between. The flats on the corners were 2.5 to maybe 3mm wide? And yeah, 1/2 to 3/4 of a thou per push was the limit even on my big lathe for that 5 to 6mm total width of cut for the last few passes. But all in all as you say, a pattern soon sinks in and the job was done in only about 10 minutes for all six corners. There is another good reason for light cuts to limit the pressure if using our lathe. Namely if there's any lift in the bed that can possibly occur the high pressure of too aggressive a pass will try to lever the carriage up on the angled prismatic ways. That's going to be hard on the contact points of the carriage to bed as well as distort the cut. I know there shouldn't be any lifting up possible. But it's not always a perfect world with perfectly tuned machines, eh?

[@MakeItKustom]

What a great video! I am amazed at the internal keyway on the lathe!

[@Blondihacks]

Thanks Karl! 😁

[@steved8038]

Thank you ,You make the difficult seem easy and explain how to get a professional result in the hobby shop .and you have a lot more style than most! .

[@imtheonevanhalen1557]

I worked in a transmission factory back in the 70s, and the job station in front of mine had a broach machine.....a freaking 20 foot long broach would lift and drop into the gears....not just a single key, but an entire splined center for the gear. It was something to see, and to marvel at the engineering that produced that machine!

[@mikeivosevich6130]

I love your sense of humor, educational and entertaining!

[@bostoncangrejo]

I was looking for a way to put a keyway slot in a gear using my mini lathe. Not only did you show me how but you offered several other viable solutions. I've learned a lot from your videos. Thank you.

[@WatchmakerErik]

Three ways to keyways! Love this. I figured it was going to end up on the lathe. I saw a My mechanics scooter restoration where he used the "lathe as shaper" technique to make the ribs in the mold for his handlebar grips. I love Saturdays 😄

[@senatorjosephmccarthy2720]

So do a small number of us. Exodus 20: 10. Exodus 23: 12. Exodus 31: 15. Leviticus 23: 3. Genesis 2: 3.

[@WatchmakerErik]

@@senatorjosephmccarthy2720 you're Jewish then?

[@MattOckendon]

This really consolidated my understanding of splines and keyways - thanks as always but you also made me chuckle and that is priceless!

[@barry7608]

Thanks love the tidy workshop, sign of a skilled and experienced operator

[@metalfabman5477]

Excellent tutorial, I've got to try this, and thanks for the tutorial without background music like so many people feel they have to add to their videos!

[@pulppeeler]

Another excellent informative primer on using already learned skills to save tons of money. I've used this method for quite some time. Now I used a shaper. If you look around there are plans for bench top shaper builds that are begging to be made into dedicated keyway cutters and would take a little larger bit. Keep up the awesome work!!

[@joeybobbie1]

Thanks Quinn for making this Video. I don’t have a Broach Set, so doing it on the Mill or Lathe will be really Handy. Please keep the Videos coming. I have really Learned a Lot from you.👍❤️

[@robertwest3093]

This impressed me enough to subscribe to your channel! I've been a machinist since 1989 and this is the first time I have ever seen a keyway cut with those methods.

[@jimparsons6803]

Liked her approach and that she thought that an old high speed drill bit that might work well enough for the cutter. A practical way to do things. Well done.

[@bostedtap8399]

Great demonstration and techniques Quinn, many don't show the release and reapply on push broaches. Thanks for sharing 👍. Best regards from the UK.

[@the_second_amendment388]

I've been watching your videos on and off for a while, very good content, and the subtle humor is a great touch, personally I think your greatest talent (machine shop wise) is explaining a procedure or concept in simple terms, on more than one occasion you have demonstrated a procedure in a way that is clear, concise and logical and yet at 57 years of age makes me wonder how I never learned or thought of doing the procedure that way before.

[@senatorjosephmccarthy2720]

All I want is a dollar for every thing I didn't think of.

[@teenaking5289]

Im a new machinist just fixing to graduate my school in april 2023. I wanted to say to you that out of all the videos on youtube, you explain things so well and i enjoy your voice. Thanks for being there for people like me. Your the best and i want to watch all of your videos and plan to do so. Im at the top of my class and already have a job offer at bowing to rehall airplanes in Atlanta, Georgia !! Love you !!!

[@jbshascommon4687]

awesome to see and hear a master of their craft...thank you J

[@DT-jz3wn]

Keyways separate the kid machinists from the adults. I have been in awe of internal keyways for years... Having assumed that they were formed on those big expensive machines. Never knew about this awesome process and am indebted! Thank you. Love your videos.

[@karls8103]

big machine better lets see her do this on a 200mm long 56mm wide keyway

[@charlesrichter3468]

Very interesting and informative for someone like me with zero experience in machining. Nice shop too. Clean

[@gregfeneis609]

Really nice, Quinn. Thanks for spline'nin it to us.

[@andrewdolinskiatcarpathian]

Excellent episode. Just what I needed. Thank you 👏👏👍😀

[@sigung01]

Brilliant! As a complete newbie who inherited a 1937 South Bend Jr. lathe with a missing 16 tooth spur gear that is essential to 90% of all thread cutting operations, and not being able to source one ANYWHERE that had a keyway, this piece of information is like a godsend.Thanks so much for sharing. I'd also like to compliment you on your teaching ability. Speaking with some 36 years of experience on teaching, I know a good teacher when I see one.

[@tnekkc]

So many things to admire about this video....using the correct terms for everything is one. Getting me to learn something new is another. In 1967 I saw a 14 year old pound an Allen wrench in the keyway slot of a go cart shaft, and hack saw off the excess. I knew that was wrong.

[@supertramp6011]

Wrong, but it probably got the job done and back out to play! I remember having to make woodruff keys for my motorcycles as a kid too- we lived in the middle of nowhere, and a vise and bench grinder were the most high tech tools we had!🤣🤣

[@AncientFlight1]

Demonstrated that "necessity is the mother of invention". Excellent!

[@TheFalseProdigy]

What a fun demonstration! This jogged a memory of when I made keyways using that mill method back in college because that specialized tool was always either being used or broken by a freshman before the end of their first week in the shop

[@johnkelly7264]

I was taught the lathe version at school in 1969 from a cranky but brilliant teacher. Your vids are just so easy to listen to. Thanks!. I had to go and have a lie down after watching the lathe method. );

[@keithfork8663]

Best demonstration of broaching I have seen.

[@iamzombie76]

You're a fantastic teacher!

[@TheCatanzaroShop]

Great video. It really goes to show how much you can do on the lathe and I love that about your videos!

[@paulskaar8556]

"Don't ever tell a lathe what it can't do". Same goes for Quinn. Blondihacks Rocks!

[@sampletaster5093]

Love this vid brings back memories. About 40 years ago I designed a part with internal keyways. The shop said it could not be done. Little did they know I worked my way through college as a machinist. Show I showed them the broach and lathe method and told the supervisor to go back to school and don’t question me again. Old folks love to challenge young kids I was 22 at the time

[@shaffer4220]

Brings back great memories in Aerospace. Great video.

[@theonlybuzz1969]

A tip that I use at my work is to get a sacrificial piece of round bar made to the same dimensions as the workpiece is of a similar material. On the spot where you are looking to have the key way, dill a pilot hole making sure that the exact centre is half into the centre sacrificing bar and half into the work piece, this with making the hole bigger (but not larger than the intended key way size ). Then you use the key way to take out remaining material. OK might be a bit more with making the centre, but it would save on how much effort is needed in the force pushing the key way to final size. Keep up the great work Blondi and have a great weekend! Phil UK

[@nerd1000ify]

If your keyway is in the end of a shaft you can also skip the whole keyway cutting step and simply drill across the join between the shaft and your flywheel, pulley or whatever, then insert a dowel pin (or the shank of an old drill cut to size) as the key. I've seen this referred to as a 'dutch key' or 'scotch key' though a round key might be a more useful description. Obviously the torque capacity will not be the same as a square key.

[@glennlopez6772]

Hello! A relief that this was not about CNC but something so straight. You have inspired many likeable witty comments! Watched the full video - very expensive! Hope you like this comment also!

[@markkoons7488]

Love your channel. Thank you for all your work.

[@trainmaxx]

Thank you for doing these videos they are inspirational. I’m not a professional machinist but I learn a lot from your videos. Your techniques are always interesting.

[@robertplace6131]

This is a fine example of a very interesting subject , in which the lecturer , focuses on the Subject , to the Exclusion of Him-self ! No tendency to focus on his face or personality issues . Better , to be left admiring professionalism of the presenter, than have him, his Voice, and his Face featured , ad nauseam !

[@David-hm9ic]

Yet another brilliant video! Love your humor.

[@ericharvey287]

That was really useful yet so simple,great tip thank you.

[@davidsawyer6784]

Educational and fun. Thanks for teaching me something I always wondered.

[@duron700r]

Oh cute! Never looked upon tiny broaches! Drool.... Then turning the lathe into a shaper. Back and forth, a little at a time. Cool. I was in the mood to turn a file into a cutter for a needed slot but used the tiny mill instead. Thank you for this! Keeps brains ticking.

[@Theballonist]

Great timing, I’ve been trying to get away from using set screws on shafts for a few months but I didn’t want to invest in a broach kit. Thanks!

[@philliphall5198]

That’s just plain cool, love it 😍 Thank You

[@billycullen4376]

Beautiful job. Takes me back to my apprentice days back in the late 70's, when I learned how to grind tools for key's and slots, and still use today. You put a lot of time served engineers to shame.🙂

[@rogerhill4427]

Brilliant. You just solved a problem on my scrap built outboard. Thank you!

[@007rgb]

So impressed. Very informative. Great video.

[@mot6021]

Great demonstration ,always great to know ways to do things without too large of a tool box.

[@mot6021]

I Have done it with files and chisels too!

[@alantupper4106]

Every time I watch you (quite expertly) grind something tiny on the grinding wheel, my heart ooches it's way up into my throat! Thanks for another excellent video

[@stevenash4973]

Great explanation Quinn. Loved the video 👍🏻

[@stevenlitkey9354]

That is an awesome tip/technique 👌 Well done 👍

[@russelkiefer8590]

Great descriptive explanation for hobby machining.

[@GBWM_CNC]

Great video! This will definitely help in future projects.

[@larrythompson2967]

I am in the process of re-powering my mill from a single phase motor to a 3 phase with a VFC. Naturally, the original motor is all metric (Korea) and the new one is imperial (US). This has made it necessary to have the mill apart while I modify the motor pulley to fit the new motor. I used the same process with some adaptions (remember, no mill). I ground up a HSS tool bit, similar to the one you made and welded it across the end of a steel bar from my stock pile. Worked fine. I confess that I have done this several times over the years, and used them in both the lathe and the mill. Good vids, keep them coming...........

[@NoOne-yt6yf]

Not only clever as heck, but a great sense of humour!

[@oiu7890]

I love your channel! Can't believe it took this long to find it.🧐

[@electromike5950]

Awesome content, you are definitely not just a hobby machinist, your are a pretty dam good machinist!!! Been working in a electric motor shop for 12 years as a mechanic and winder and im getting into the machine shop as much as i can when possible and loving it so much. its hard to hired new machinist that can repair stuff without a fancy drawing. you definitely can! On this one i will be able to pull of something the old guy probably never saw! Don't worry i will give you all the credit just after seeing his eyes widely open :)) Thanks a lot for that great channel

[@andrewmiddleton3214]

Thank you for your video, you've explained excellently and simple steps to "your fantastic"

[@mitch3384]

"Chamfers are what separates us from the animals".. love it. 🤣

[@darrellhart9363]

That seams similar to rifing a barrel and you made it look very easy to do. I did one time had to change the size of the key with only files so much fun and time. It did work.

[@Austeration]

Great job 👍 thanks for sharing your knowledge. Lots of lubrication on the innie and outie bit on the lathe. 😁