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Rotary broaching is a process by which you can make certain types of non-round
holes in parts,
the classic example being the hex-shaped holes in allen-head bolts or Torx
The process is fairly straightforward, but the broach holders tend to be
rather expensive, often selling,
even used, for $300 to $700. As of this writing, I'd been tooling up a small
turret lathe, and decided I'd
make my own broach and holder for it, in anticipation of a few projects I
have in the pipeline.
I started with a bar of "mystery metal" mild steel from the scrap bin that
started out about 7/8" in diameter.
I turned two .500" steps on either side of a boss that was about .275" wide.
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