| | No Keyway? No Problem!!! | |
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Age : 51 Join date : 2013-04-21 Points : 7201 Posts : 2914 Location : Ontario Canada
![No Keyway? No Problem!!! Empty](https://2img.net/i/empty.gif) | Subject: No Keyway? No Problem!!! October 14th 2013, 8:20 pm | |
| Recently, I had to hand cut new keyways into MULE's new axleshaft. Instead of a fresh write-up, here's one I did almost exactly a year ago. My trusty Tecumseh H60 had a Woodruff keyway (1/2 round) in the PTO shaft and I needed a full keyway so I cut it in. Cutting a keyway into any shaft comprises the same thing. Remember to work slowly and check your progress often. Here's the article:We've talked about cutting your own keyway on this forum before. I just ran into exactly the right situation to address this. I know that others have done it, but not much has been written. Unfortunately, the PTO shaft on my trusty (and becoming notorious) H60, did not have a standard 3/16" keyway cut along it's length. What it did have, was a Woodruff keyway. A woodruff key is a half-round piece of a specific length, rather than a basic rectangle of variable length. What it means to you, is that no regular shaft components will fit. you're either off to a machine shop to have a standard keyway cut, or you're doing it by hand. So I did. I used a length of 3/16" rectangular key stock, a small square, and a hardened steel scribe to mark the location on the shaft. Here's a tip- if you have a hard time seeing your lines, spray a very light coat of paint on the shaft, then re-scribe the lines. I had to do this on my axleshaft. Then, I put a thin kerf cutting wheel in the flexible shaft extension for my Dremel. Using the cutting wheel, I "traced" the scribe marks into the shaft, to the approximate depth required. I took off the cutting wheel and installed a grinding wheel that was a little less than 3/16" thick to remove the centre of the keyway. Carefully and gently, I ground the keyway, pausing every couple of minutes to check my progress and let the shaft cool. To check progress, I used a 3/4" bore LoveJoy coupling and the same key I used to mark the shaft. Once I reached the point where the key would just fit between the shaft and coupler, I cleaned it up a bit and called it done. I apologize for the dark, crummy pics. I used my phone, and I was racing dusk. Remember- work slowly and check your work often. Don't force the tool- cut and grind gently. This not only extends the life of the bits, but reduces the chance of slipping off your line and creating a mishap. ![No Keyway? No Problem!!! Key110](https://i.servimg.com/u/f56/18/25/82/69/key110.jpg) The shaft in an unaltered state with the Woodruff keyway. ![No Keyway? No Problem!!! Key310](https://i.servimg.com/u/f56/18/25/82/69/key310.jpg) After tracing the lines with the cutting disc. ![No Keyway? No Problem!!! Key510](https://i.servimg.com/u/f56/18/25/82/69/key510.jpg) Progress pic, about halfway, checking with the key. ![No Keyway? No Problem!!! Key410](https://i.servimg.com/u/f56/18/25/82/69/key410.jpg) Very nearly finished. It was too dark for a picture after I cleaned it up and called it finished. Start to finish, including very carefully measuring and marking the location, was about 40 minutes. DIY, baby, DIY! ![No Keyway? No Problem!!! Dremel10](https://i.servimg.com/u/f56/18/25/82/69/dremel10.jpg) EDIT- Upon request, I have added a pic of the "Dremel" and accessories I used. In this case, the tool is a Dremel-like mini electric die grinder with a 1/8" collet. Accessories include a flexible extension shaft which you hold like a pencil and allows excellent dexterity. The cutoff wheel is a 1.25" diameter fibre-reinforced abrasive wheel with a very thin kerf. The grinding wheel is an abrasive type, 3/4" diameter, and about 5/32" thick. Not shown are a sharp carbide scribe, a 3/16" x 2" key, and a small square. | |
| ![Go down](https://2img.net/i/empty.gif) | | crazykid1994 Established Member
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Age : 29 Join date : 2013-03-18 Points : 4808 Posts : 618 Location : loxahatchee, florida
![No Keyway? No Problem!!! Empty](https://2img.net/i/empty.gif) | Subject: Re: No Keyway? No Problem!!! October 14th 2013, 8:29 pm | |
| thank you. i may have to do this if i ever get to upgrading the brakes on my murray. | |
| ![Go down](https://2img.net/i/empty.gif) | | redlinemotorsportts Moderator
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Age : 27 Join date : 2013-03-18 Points : 7366 Posts : 3131 Location : raleigh nc
![No Keyway? No Problem!!! Empty](https://2img.net/i/empty.gif) | Subject: Re: No Keyway? No Problem!!! October 14th 2013, 8:37 pm | |
| Looks easy and nerve racking. You have 1 shot... I guess when push comes to shove, you dont really have alot of options. | |
| ![Go down](https://2img.net/i/empty.gif) | | Doc Sprocket Site VIP
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2018 Build-Off Entrant
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Age : 51 Join date : 2013-04-21 Points : 7201 Posts : 2914 Location : Ontario Canada
![No Keyway? No Problem!!! Empty](https://2img.net/i/empty.gif) | Subject: Re: No Keyway? No Problem!!! October 14th 2013, 8:51 pm | |
| That's why you just go slowly and carefully. Pardon the pun, but patience is the "key". And I'm far too cheap to pay a machinist if I can help it! | |
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