Here is what he did:
- The mill is NOT turned on
- He used a broaching tool that he handmade
- The tool is stroked down by HAND for each spline, and all 32 splines are done to a shallow depth first, then broached a little deeper on the second pass, a little deeper on the third pass, and then custom fitted to the steering box shaft via .002" cuts until the tapered spline goes onto the shaft JUST far enough.
- The rotary table is roated eactly 10 degrees each time (32 regular splines plus 4 master splines = 36 splines in 360 degrees, or 10 degrees per spline
- The hand broaching easy when done just a small depth at a time, and with a tool bit that is much harder than the steel.
Jim G
