Square Hole

[Parm]

How easy is it to make a blind square hole in the end of some hex bar?

I want to make a key for a square drive. Finished dimension of 11.5 mm square

it only needs to be about 25mm deep

I’ve got a baby millng machine, lots of cutters, lots of stock and plenty of time

is this possible?

 

[Paul.]

I would cheat!,
Use the lathe to bore out a short piece 25mm long for the key end, then broach it or file it out square to fit, then weld it to a handle, I've done similar things in stainless for adjusters on various items of food machinery, adjustable feet, conveyor tensioners etc.
Alternatively just fabricate it from four pieces of flat, polish it up to lose the welds and then stick a handle on it

 

[MCKDAVID]

drill it, and file the corners out square, wee rat tail files, wouldn't take that long. easy to over think these things..

edit, aha paul beat me to it, great minds etc... hahah

 

[Screwdriver]

Rotary broach. Plenty of YouTube vids out there.

 

[123hotchef]

i cheated too! purchased some box section 3mm wall with the right size hole and welded it to a old spanner for my mill vice square drive, saved me loads of messing about

 

[pressbrake1]

Theres lots of ways
Hex is normally free cutting so easy to work
Drill hole to size then machine under cut at base of hole(if material size allows it) notch out corners hss square tool in lathe tool post. Almost like a slotter
Or you can make a crude rotary broach

 

[earthman]

I drilled a hole in each corner, used end mills to remove the rest of the material and tiny files to try and clean the 4 sides up.

 

[Parm]

I drilled a hole in each corner, used end mills to remove the rest of the material and tiny files to try and clean the 4 sides up.

this exactly the plan I have in my head

just need to make it happen

 

[brightspark]

this exactly the plan I have in my head

just need to make it happen

just drill 4 small holes in the corners. less to file out

 

[slim_boy_fat]

Didn't @doubleboost cover that very 'how to' in one of his SSSs?

 

[Ali]

I keep trying to think of a way you could broach it on your newly finished little press. You could do it but an awful lot of messing about to get set up.

What’s the square tool intended to be offered up to?

 

[Parm]

I would cheat!,
Use the lathe to bore out a short piece 25mm long for the key end, then broach it or file it out square to fit, then weld it to a handle, I've done similar things in stainless for adjusters on various items of food machinery, adjustable feet, conveyor tensioners etc.
Alternatively just fabricate it from four pieces of flat, polish it up to lose the welds and then stick a handle on it

I’ve thought about welding and polishing, but my welding skills are rubbish.

Broaching is something I will have to look into

 

[Parm]

drill it, and file the corners out square, wee rat tail files, wouldn't take that long. easy to over think these things..

edit, aha paul beat me to it, great minds etc... hahah

I’m looking for a solution that don’t require blood sweat n tears

 

[ronan]

I used the carriage of the lathe like a shaper to make a square hole. A ground piece of HSS and it worked a charm. You could mill out the majority of the material and clean up the corners with a small diesinker chisel (easy to make from a bit of silver steel). Depends how accurate you need the hole.

 

[Parm]

I used the carriage of the lathe like a shaper to make a square hole. A ground piece of HSS and it worked a charm. You could mill out the majority of the material and clean up the corners with a small diesinker chisel (easy to make from a bit of silver steel). Depends how accurate you need the hole.

I’d never thought about doing it on the lathe.

I have plenty of stock, an ok lathe, some silver still and other stuff.

Worth adding to my list of options

 

[eLuSiVeMiTe]

I want to make a key for a square drive. Finished dimension of 11.5 mm square

Half inch square drive socket upside down.?
Doesn't need to be a snug fit for a square drive.
Turn to size and Weld ur handle of choice on
Or size the socket to fit your hex bar

 

[ronan]

 

[jsf55]

Have you tried a good 12 point socket to see if that would fit, probably 7/16ths at a guess ?

 

[Parm]

Have you tried a good 12 point socket to see if that would fit, probably 7/16ths at a guess ?

That’s the correct size but I dont have one

 

[eLuSiVeMiTe]

That’s the correct size but I dont have one

Probably have several