Shaper Keyway Cutting

Some new quadrant gears for the Holbrook lathe require keyways to be cut - something new to try. A quick walk around the Elliot 14S shaper, the keyway tooling and then we see how we get on.

[@terrycannon570]

Always love the shaper videos. Thanks for bringing us along.

[@craigtate5930]

Nice lil project. You mention setup taking so long on your shaper. You aren't alone on that. Probably one of the top reasons I don't use mine terribly often

[@lookcreations]

Its one of the 'skills' that get better each time you do it. So roughing off is now pretty quick.

[@donlaughinghorse9651]

Hi Mat, I've been watching your back catalogue, got to the holbrook apron rebuild. It's been , overall, very educational, particularly the scraping. I live just a few minutes from you, so , if your stuck for a hand, give me a shout, I'll be glad to help if I'm able.

[@lookcreations]

Hi Don - its a small world with youtube - glad youve found some of the content of interest / educational. If you are passing feel free to call - if Im free there's always a brew only minutes in the making. Mat

[@donlaughinghorse9651]

@@lookcreations Hi Mat, where exactly are you? Is it Milton Lane area? I'm only at Batham Gate, so I'm in Chapel quite a bit.

[@swanvalleymachineshop]

Nice job . A big job for the small lathe to do the gear blank on . Cheers .

[@lookcreations]

Not quite the biggest part Ive had in the Boxford lathe but getting up there. I think the shaper crank shaft was heavier and certainly longer and a lot more material removed to give me a shoulder. But I have to keep the weight down or speed down as thelathe doesnt have the mass to soak up the vibrations - even though it is bolted to the floor slab.

[@CraigLYoung]

Nice to see the shaper running again. Thanks!

[@lookcreations]

I do enjoy using it Craig. All the best Mat

[@trialnterror]

I bought a broaching kit years ago and just cut my first keyway’s last weekend for my Cnc pulley’s!

[@lookcreations]

I wanted a broaching kit, I have a good sized fly press (No.6) but even thats a bit restrictive on the thickness of part which can be broached and still fit in the press. I think a home shop hydraulic press is the way to go. Glad you got yours in to use :-)

[@trialnterror]

lookcreations I bought the 12 Ton press from harbor freight which got it done. (With a lot of pumping!)

[@grahamsengineering.2532]

Hi Mat. Nice video. I always do my keyways at the bottom of the hole. More rigidity. I have a 22" Strigon Toolroom Shaper, made in Hungary 1967. I'm making tools as needed for it. And like you am looking at ways to set up quickly. One thought I've had is a removable taper cone to slip over the end of the tool to pick up the end of the hole. Cheers.

[@lookcreations]

Hi Graham, thats an idea for centring the tool - but it requires the tool position to be used as the datum or the hole hmm got me thinking that ! All the best Mat

[@bcbloc02]

I don't own a shaper so for the odd keys I don't have broaches for I have to just use a bit in a boring bar on the lathe and use the carriage to cut my keys. Despite the tedious setup here this method seems more convenient. :-)

[@lookcreations]

Ive used the carriage on my little lathe to score graduations and the likes - never a keyway as Ivenot needed one until now - but even a few thou' deep score tool two or three bites and on a dial it took an age. The shaper has proven to be a handy addition in my little shop Brian. Im sure you could find a corner for one in your 'estate' :-) The best bit is tooling is chicken feed and you could soon rig up a fixture for dedicated keyway cutting. All the best. mat

[@TrPrecisionMachining]

very good video..thanks for your time

[@lookcreations]

Thank you. All the best Mat

[@rgmoore]

Matt, that was a great trip down memory lane to some splendid key way cutting. Those look awesome! I saw the fan in the floor for the black-smith setup you were considering. Thanks for sharing!

[@lookcreations]

Still going to do the forge - been investigating how to run one 'quietly' so looks like I will haveto sort out my fly press and tooling for the larger jobs. Hopefully on the home straight now with the Holbook and once running it should let me stand back and progress a few of the longer term projects like teh forge. All the best Russ. Mat

[@GoCreateHobbyMachineShop]

That arrangement you have with the VFD looks very good in the way you can control the ram. The local Men's Shed asked me about a 14" Alba shaper they have, to my amazement I discovered that a clutch was an optional extra, the one they have has an inch function for set up, the machine is not operational yet though. I have an Elliot 10M, it's my favorite machine to use. Enjoyed your video, I've got some keyways cutting to do in a couple of weeks.

[@lookcreations]

I had the 10m , very useful capacity in a small footprint. I had a couple of jobs where I needed a bit more. The clutch on it worked well, but not so easy to feather/inch. The vfd and inch switch is really handy.

[@AGEngineering]

That worked well Mat, economical compared to buying broaching kit

[@oldschoolengineer58]

Excellent Work, Thanks for sharing

[@lookcreations]

Thank you! Cheers!

[@carlwhite8225]

New Guy here, Have been watching you on FB, Love your channel and have been watching the shaper resto vids. Greetings from Kennesaw, GA, USA.

[@lookcreations]

Welcome aboard! Carl, glad you like the content, feel free to share the channel with your friends - more the merrier. All the best Mat

[@MatthewTinker-au-pont-blanc]

I've had my 10M Eliott about 15years, it's principal use is cutting key ways. I haven't tried it in reverse (I haven(t got round to wiring in a reversing switch) which is another option, in reverse clapper locked 'either way up) can reduce chatter, like a rear mounted parting tool on the lathe! You can reverse yours, could be useful one day!! Cheers, Matthew

[@hilltopmachineworks2131]

Thanks for the shaper action. I still havent had a chance to cut any keyways with my G&E yet.

[@lookcreations]

Glad you enjoyed it. Got a bit more lined up over the next couple of weeks. Thanks for stopping by Mat

[@philhermetic]

Nice video Matt, and excellent work. First time I used my shaper in anger was to cut an internal keyway, but I like your tool much more than the one I built, and I have one of those shaper universal tool holders, so there may be one in my future! I have an Alba new 1A. Phil, East Yorkshire.

[@lookcreations]

Hi Phil, I am quite ashamed that Ive had a shaper for 5 or more years and only just cut a key way !. I am thinking of what mods to make on the tooling to ease set up. I know a lot of chaps remove the clapper and mount it fixed - not keen on that as the fixing that holds the clapper box support is a swine to say the least ! What ihave works so I will have to see how things develop in terms of requirements. All the best mat

[@philhermetic]

@@lookcreations I think you have cracked it Matt, as you showed in the video, set up can be difficult, but once you get to appreciate the paraneters of the machine, it gets easier. I had exactly the same problems! Your set up is more rigid than my mk1, which was a lump of rectangular steel which was a good fit for the toolpost, with a suitable round bar welded to the end. It worked, but I got the grind of the tool wrong, which is most important, and also was not rigid enough, probably because of the incorrect grind. I will build one like yours, and also copy your grind next time. I am not keen on taking off the clapper and going straight into the ram either. I like your clapper box lock, I drilled and tapped an allen screw into mine. As far as I understand it, the only reason to lock the clapper box is to prevent the tool and holder catching on the top of the bore on the return stroke, although with your set up, working inverted needs it as well! I cut my keways in the bottom of the pulley.. Is there any other reason you know of? Phil

[@NoelBarlau]

Beautiful. Nice job.

[@lookcreations]

Thank you! Cheers!

[@ROBRENZ]

Enjoyed! ATB, Robin

[@lookcreations]

Good to see you Robin

[@paulhammond7489]

Just recently found your channel, right chuffed I did... Grand job on those two keyways BTW: Now to allocate some time to watch the Elliot 14S shaper rebuild :)

[@lookcreations]

I’m glad that you’ve found some interest in my channel. It’s not to everybodies taste, but it’s honest small shop stuff. Enjoy the shaper rebuild I learned and shared a lot of lessons on that project. All the best Mat

[@paulhammond7489]

@@lookcreations Got as far as Ep-11 (so far) Obviously I know you have it working now, but impressed that you stayed with it after the encountered hurdles that you found so far. Enjoying the trip down memory lane and the small Northern shop honesty :) Will catch a few more episodes in my morrow! Happy to have found your channel..

[@markgrevatt4867]

Love the shaper matt. Can't believe the price you paid was an absolute bargain. Look forward watching the shaper rebuild on your channel

[@lookcreations]

Hi Mark, the shaper was in a pretty poor state when I got it - but I wanted to learn some new skills and in pushed me to do just that. I hope you enjoy the series. All the best Mat

[@markgrevatt4867]

@@lookcreations well mat you did a great restoration on the shaper. What i can see. I look forward watching your videos on the shaper restoration.. I'm in the process of building my ( small ) workshop and looking forward restoring my Harrison L13 lathe. Which I'm itching to make a start on. Long way off though. And she needs some TLC to bring her back to good health. So alot of fun work ahead of me. Although I' have no intention on planning to start a KZbin channel. I leave that to the more confident professionals. Thanks for sharing mat. Enjoying your channel. All the best buddy.

[@woodscreekworkshop9939]

Beautiful shaper!

[@lookcreations]

Thank you! Cheers!

[@dazaspc]

That is the way to do it because if you have even the slightest misalignment in the clapper box you take the edge off the tool and rub hard enough to bring the key way out of tolerance. Also if you look at any slotter may be 1 in 20 will have a clapper box and they are usually fixed. Most Shapers when they were earning their keep were usually set up to do repeat jobs so setup wasn't quite as big an issue not having hand controls. Also many that used an overhead system incorporated that side of things in the overhead belt side ie idler pulleys. Nice job BTW

[@lookcreations]

Thank you. I was apprehensive about the job being new to me, worked out ok though .

[@TidyThreads]

Think yourself lucky, The machines i use everyday have about 96 oil holes on each machine. My first job in the morning.

[@lookcreations]

thats a lot of little holes to find ! thanks for stopping by and commenting. All the best Mat

[@MattysWorkshop]

Gday, you really did a beautiful job restoring the shaper, I have a 11” stroke PK Douglas shaper and absolutely love it, favourite machine in my shop, when I built my new shop I got some sheet metal folded up and I welded the corners to make big trays, I sat the shaper in one, the power hacksaw has one and my old lathe, just a simple at to keep things clean, I made a similar key way cutter also but only used it once to see if it worked and never needed to use it since, those gears you you make look really nice and should serve the purpose well, great video, thank you. Matty

[@lookcreations]

Hi Matty - I think my frined in Oz had and sold a PK Douglas - then purchased a bloody great bit british shaper. If I can find a link I will post it - Greg' does some great work in difficult on site situations getting stuff out of tight spots. I think his KZbin channel was 'The Barn' but I will check. All the best Mat

[@TheKnacklersWorkshop]

Hi, I'm a new subscriber and enjoyed your video... as an apprentice i used a shaper and remember all the oiling up before use. I wish i could remember what make of shaper it was but many moons have past. I will check out the restoration playlist of your shaper. Take care Paul,,

[@lookcreations]

Hi Paul. I know the shaper has a good number of oil points - I added a couple on the ram. But hands down the Holbrook lathe at least twice if not three times the number. Ive spent half a day screwing in little oilers - I can fully understand why machine makers moved to central lubrication systems and charged as an extra - the man hours saved over a feww years would easily pay back. All the best mat

[@e.d.s.inc.shandon9133]

Nice Work Matt! I have yet to make my first keyway. I have a project coming up in which I will need to. Debating on whether to get a broach set, or use the slotting head on my Ajax mill.

[@lookcreations]

I have a fly press - quite a good sized unit and was thinking about the broaching option - but the tooling for even just a single keyway broach was silly money vs the number of times I am likley to use it. Besides I have a shaper ... The tooling could have been made mucj more straight forward and I may well make a second holder to fit the bars. A slotting head is a useful bit of kit - it can square out holes, cut keys etc - well worth making up the bits and learning how to make best use of it. I know the feeling is 'new tools' going to be far quicker in the end - but really is it once youve learned how to do the job ? Thats what I am trying to get o , learn how to make best use of what I have before spending more hard earned on new tools. All the best Mat

[@hasanosman171]

لقد احببت اهتمامك بالالة هكذا يكون الفنان

[@RobB_VK6ES]

Picking up dirty habits from the yanks. Put the compound slide parallel to bed then you have a well calibrated method of facing to length as well as there being no chance the set cut will change should the compound move. Here in Aus every turner I have seen in 40 years has the compound parallel. Direct plunge threading is fine up to 3mm pitch and you cam creep the compound to compensate for incorrect tool nose radius.

[@lookcreations]

Sometimes I do, but when cleaning out the corner like this with the rebate on the gear faces, it helps to be able to come in a slight angle. Do the 'yanks' have bad habbits ? :-)

[@craigtate5930]

Something on your floor to the right side of the shaper caught my eye. Something with what looks like a round aluminum housing with a ton of cooling fins. I was wondering what that is?

[@lookcreations]

Its a blower fan Ive modified to set up and use as a furnace blower for a small forge. Its all but finished. Had to call a holt on the forge for now as the noise levels will cause issues with the neighbours. Ive a fly press to hopefully resolve that when I get back to the forge project.

[@craigtate5930]

@@lookcreations got ya. I have seen blowers like this. Serious blowers! Just didn't recognize it in the video. Thought it was an engine, or mini nuclear reactor or the likes..lol

[@machineshopatthebottomofth3213]

Mat, I have a 10m like your old littleun. I bodged together a fixed bar holder to replace the clapper. May be I missed it but how did you go about centering the cutter? I usually scribe the sides of the keyway, but it’s a bit of a faff.

[@lookcreations]

When I made the cutter I made it exact width of the key - I then eyeballed down the hole moving left / right to get both corners of the cutter just scratching the bore. Oh it also requires the cutter be ground well - 90 degrees at its tip lets just say, I didnt record the cutter grinding by hand ... and the fact I got through a few bits of HSS in the process. But next times goingto be easier - grind the tip and relief to the base of teh tip - grind the sides last once you have the tip right & DONT OVER GRIND THE SIDES AND LOSE THE TOP CORNERS ... if you get what I mean :-) Bringing the cutter slowly into position just takes a bit of trial and error - but I think it worked pretty well - the collar the gears sit on is well made by holbrook - if there was any significant error in the keyway it wouldnt have fitted. Good to see you commenting. Hows the series after the lockdown ?

[@machineshopatthebottomofth3213]

Thanks, took the landy out a few weeks ago and it conked out going up a hill. i think it must have been condensation in the carb as i got it going again and it was fine. its done about 50 miles in the last 6 months, poor thing. Its not the best to have it just sat there but pre lockdown i was on the push bike most of the time and now well i am stuck working from home....

[@therealspixycat]

Can you do a video on how to properly set up the shaper and explain every step? For those of us that have no knowledge of using a shaper? I just bought a shaper and have never used this machine

[@lookcreations]

Ok I can have a go - but if you get a chance search Google for 'Shapers' set up - there was a website in the US dedicated to shapers - and on it there was a really good set up procedure check list. MEME I think - but it was a long time ago when I went through it. Also take a look at and join if poss' the Groups IO site for shapers and planers - loads of useful info on there and the group members were alwasy very helpful - there is a similar group on Facebook. Lots of helpful info' out there now that was pretty hard to come by even five years ago. All the best Mat

[@therealspixycat]

And I am going to watch how you restored this shaper to get I hope a good idea of what the state of the shaper I bought might be also about 30 pounds... i hope not but I have no idea. Thanks again for your excellent video's

[@lookcreations]

Hope you enjoy it!

[@therealspixycat]

@@lookcreations I am watching the rebuild of the apron and gearbox. Very interesting to see how you tackle this precision job. I have worked on a similar Boxford lathe that felt on the small gearbox and broke the part underneath the gearselector pins 🤨

[@therealspixycat]

How do you determine the exact alignment of the cutter when measuring it?

[@lookcreations]

@@therealspixycat whic cutter ? For the key ways ? I ground it much like a pating tool taper out to the tip, Tip width to excat width of the key.

[@therealspixycat]

@@lookcreations I mean you have to find the exact centre right? On the mill you use a puppy taster to find the center

[@samrodian919]

Nice job that Mat, especially as it's your first keyways, one question are the bores of both gears the same? If so why didn't you set them both up with the mandrel you turned them on and put them together in the shaper vice and do the keyways both together? It would have saved you a lot of time. Also I certainly would have cut the keyway in the bottom of the gear and put the gear(s) as low as possible in the vice for further rigidity and more surface contact. But you made a bloody good job of it mate, well done! ( I know I'm years behind watching this in 2021 but I've only just found your chanel and am randomly catching up, i binge watched the ?Holbrook lathe episodes after subscribing from the first episode)

[@lookcreations]

I ran them seperately as that was 'lower risk' of cocking them up. I ran them inverted as that was what I had read. Not sure its much of an advantage certainly not as far as lubrication of the cut goes. On the other hand, it all worked out well and if it aint broke dont fix it applies ... :-) All the best Mat

[@mosfet500]

Too snug, you might have trouble if you ever have to take it apart. I like .050" min on top of my keyway with the key in.

[@lookcreations]

Yes, I was a little concerned - found a small burr on the key top corner pushing sideways - now it slide on and off as the orginal.

[@janvanruth3485]

cutting a keyway upwards seems wrong to me the play that will come into being every time you adjust the depth of cut will have to be taken out by the tool every time. in cutting downwards there will no play as the movement is against the cutting forces.

[@lookcreations]

I’m not 100% convinced about inverted cutting. Once the clapper is locked, the tool deflection has to be accommodated. Cutting lube runs out the joint etc. Where as if it’s cutting down and the clapper is locked tool deflection is still evident but lube runs in and that helps. I was going to try both, but due to time figured the first method worked fine ... better than expected so repeating it was easier than rotating the tool etc. Thanks for watching and commenting 👍