A friend of mine came by and asked if and how a broaching tool could be made.
He wanted to "index" a outside ring onto a inside cylindrical part. The inside part and be drilled with apropriate sized holes easy enough and the excess turned off in the lathe.
But the inside matching pattern gets a bit trickier.. So i thought this up, a piece of 40mm steel will get slots milled into its outside diameter with a fullradius mill, and then tapered in the lathe to a 1 degree taper. Then "teeth" will be put into the piece (maybe they are upside down). and the contraption get case hardened. The rings will be made out of aluminium so i imagine this could be forced through them with my 10 ton shoppress and is sharp enough it will cut the inside pattern he want.
