Internal Splines (and Hexes Too)

Locktite????

Who is this book

Why 304 vs 4140?

Good job on the workmanship and the video, I would have probably just welded it together😮 just kidding

Very nice video of making parts that match through trial and success. I especially liked watching the test runs before taking on the final piece.

This explains why good broaches are expensive...........

Some 60 year olds have 1 year of experience, 60 times.

I wonder what Kurtis@Cutting Edge Engineering or Brandon@Inheritance Machining would suggest? I will say your… channel is refreshing!

YES BUT.....
WHEN THE ELECTRICITY IS CUT OFF AS NO CUSTOMERS HAVE PAID YOU....
THOSE MACHINES DON'T WORK.

Very neat well done

Really impressive work.

Definitely a master 😎👍

This was great to watch, I’m a retired automotive engineer and have always been fascinated by one off projects like this. Bravo!

Hola, donde puedo comprar ese libro?

I had the same problem with a tool sliding in a boring bar while single point threading some ACME nuts for a project. What I did to stop the problem was grind a small groove in the side of the cutting tool so the set screw had something to locate on and bind in. The tool never shifted for the remainder of the job once tightened in place. Another solution I have seen is to bore a small hole in the side of the boring bar the intersects the square hole and tap it for a second set screw. With two screws the tool is held more securely an is less likely to slip.

fk that. . . . . . just cut the 2 bores and use set screws. redneck fix.

Handled it like you've done it a million times before!!! Three thumbs up!

👍🏾👍🏾👍🏾👍🏾👍🏾

Now I see what needs to be done to attach a pinion shaft directly to a tail shaft for a mid-engine design.

Jeremy, I recently watched quite a few of your videos. You're kind of rough and don't care for looks too much as long as it works next to your dedication of reusing crusty old pieces of material again. I agree totally; as long as it works for me I'm golden. If it's for a client I get anal about everything to be sure they pay the bills and return sometime. I also learned that you seam to know what you're doing ;-) So my question to you, Jeremy the metal Mc Gyver, I can repurpose any lump of rust into a functional piece again, what's your background? Just curious and loving your work and humor or a fan. Curious about your answer. Thank you Jeremy, Best! Job, made a ton too...

Really like you content and the way you revive old tools, also think you are funny. Thanks for making all of your videos!

Why didn't you just reshape the spine? For what you were doing reshape to a hex would've been so much easier and probably last longer.

You can't just 'Muscle' your way on a Job >> Take your time > Plan it, calculate your intentions, use a little Visualization !

Bloody knuckles are a sure sign of a master machinist

We saw it! Nice job!

A masterful piece of work and patience! No more buying broaches for me, I've got the shaper, heat treat oven and oil so no excuses. Just a note on the hex holder tool you made, if you part off a little brass disc and put it into the grub screw hole before the grub screw, you won't get all those marks from the screw tip on your nice hex mount tool 🙂

So that was most likely originally coupled by a plastic coupler. Similar to vacuum pumps. Stops the motor wiping out ifn the pump eats itself. Thats why the splines are oddball

turbo encabulator 😂 a fine binky easter egg

Nice work. Try to punch on the spline tool u made on side where the locking bolt rest. So that it locks with the hex threaded bolt u used. And the tool wont get shifted. Best of luck.

Dang, splines and the like are so labour intensive...

Admire your skillset ...and your patiience in seeing the project to the end.
Thanks for showing the mis-steps as well for us imperfect learners out here.

I want to know if you can give me some advice on buying my first lathe, I know how to use, not as well as you but I'm trying to make sure I don't buy crap, mini lathe is what I need. Love your vids, I've learned a lot.

So, when are you going to get going with that turbo encabulator on your list?

Hey! Quick questions, for an aluminium driveshaft, is there any way to tighten the splines just a little? It has a really small play but that play gives me vibrations at 80kmh+ and a small clunk. It just need a small small correction

Impressive. Cheers.

Mad respect for the skill, patience and commitment. Great work!

I really like the fact you had to make a number of "tools" to finally get to making the project. Seems to happen to me on my projects (now retired so I can take all the time I want). Also, finding that what I think should fit on 1st try .... well... you know. THANKS!

Well done! I would suggest you wire-brush the rust off of your material before you deteriorate your collet faces and chuck jaws with iron oxide abrasive.

Next time, if you have access to a comparator you can use epoxy to make a copy of the shape on the splines, align it on the comparator and find the exact angles and measurements you are looking for, lightly coat the splines with oil, anchor lube or Vaseline to keep the epoxy from sticking, it works perfectly and no much need to hunt for information.

Great job on this build, I did learn some points on how I can do better next time. Thanks.

hey do you want to come over for a dinner? I also have some nice homemade black berry jam that i would like to gift few jar of it to you. After the dinner you can possibly cut some splines on an axle for me :)

Well this is weird, random video on Sunday morning, I’m 24 seconds in, was this veteran memorial in Franklin, NH. I’m also from the area so cool to see local content

Thats a heck of a coupler!

Great work on the slotting, Although I would recommend using the standard tooth to slot the correct profile. Seem like an application in which high RPM is experienced, its prone to quick wear and mismatch. You should be able to hear it with time (if occurs).

Wow It's different

As a hobby machinist trying to understand these machines, I appreciate what you did, and how you thought it out. And you did it as a project that will make people happy is a bonus.

I do have to ask, though... Do the motor and pump still work?

You rock stop selling your self sort keep kicking ass

Spur gear fixing mark

For your backing out problem you had with the hss cutter in your spline maker, try putting in a center drill divit where the set screw seats. It should greatly reduce the chance of it backing out and loosing your measurements

hoping the pump was worth it! Gotta make sure it's properly matched with the motor and both worthy condition of such repairs and installation, but your metal work was beautiful! Thanks for sharing and teaching the craft!

Great video. Loved seeing the way it is actually done not just a perfect edited video like most vids

A couple things keep coming up in the comments, so I figured I would address them here:
In getting ready for this, I was able to find the pats diagram for the pump, it shows a one-piece, rigid coupler attached to the shaft. In fact, the shaft and coupler are listed as one part number. It’s not a lovejoy or other sort of flexible coupler. And yes, the fit on the spline as shown is probably a little tighter than it should be, but after several rounds of assembly and disassembly, the fit did loosen up a bit. I’m assuming there are some small burrs in there that got knocked down. If I had to do it over again, I probably would make take another .001 off. Additionally, the hex shaft is about .003” under the nominal dimension, and I made the broach to the nominal dimension, so there’s some wiggle on the connection on the hex end, so I’m not particularly worried about misalignment or vibration issues. Also, a flexible coupler probably wouldn’t have fit in the pump housing.

The other two things that come up are 1) why not modify the shafts, and 2) why buy something to make it work. The answer is: because Jeremy Makes Things. I wanted to see if I could do this, and do it as close to the right way as possible. I knew the theory behind doing an internal spline, but theory and practice are two different things. I wanted to push my skills. As happy as I am with the end result, this project was just as much about going through the process.