Internal Splines (and Hexes Too)
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- เผยแพร่เมื่อ 17 พ.ย. 2022
- This is probably the most complicated part I've machined. A friend asked if I could make a shaft coupler that had an internal hex on one end, and an internal involute spline on the other. Since I have a metal shaper, I said I should be able to do that... Of course, I used every other machine in the shop in the process. I ended up cutting the spline on the shaper, but made a broach for the hex end, following the method shown by Clickspring in this video: • Spare Parts #13 - Maki...
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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.
You're doing an awesome job here, I hope you don't feel the need to justify all your decisions to any naysayers out there. Great to see you pushing your skills. Just keep on keeping on, you're doing all the right things 👍
G'day from West Australia🙂
As a 3rd gen engineer with 40yrs of trade life.
Well done buddy well done indeed.🙂👍👍
Well said. Thank you for a great video, I learned a few things. Awesome.
Jeremy makes things, not Jeremy buys things.
How much did you charge
I just love when somebody else volunteers your services
Nice to see a machinist who is more about the work and less about the image and vanity. Great to see real old school tools being loved and worked. Subscribed on first go.
I love your "toolception". Making a tool, to make a tool, to make a part to fix a machine.
You know you achieved complete machining self-reliance when “That’s probably not the last one of those I’m making” Is followed by making a goddamn broach. And to prove it, just make another one! Awesome job!
We had a spline shaft come in pieces, to the shop. I made a series of kerfs, carbonized it, and heat treated. Made a short broach to clean up the spline. Used a dividing head for the shaft. I think you should always knurl, as slow as it goes. Too often, the knurling wheels, weld on to the pins. Can't keep enough oil on them, knurling can produce a lot of heat.
This was great to watch, I’m a retired automotive engineer and have always been fascinated by one off projects like this. Bravo!
Jeremy, Thank you for sharing your (mostly) entire thought process plus the "oopses" that you ran into instead of doing like most channels that "hide" their mistakes and other things that don't go correctly. Seeing how another home shop Machinist goes about a job with similar (actually better! ;) equipment and raw materials is very helpful as well as giving an idea of that "aw sh**s" to expect is worth its weight in TH-cam gold!
That was my favorite part too. A lot of machinists channels will show a failed part, describe what happened and a quick shot when they chuck it back into stock. I like that here he shows exactly why it messed up and even keep going until it’s beyond repair, exactly what I would do 😂.
None of that perfect machinist crap, just what will get the job done is encouraging for a hobbyist like me.
I was really impressed not just by your skills, but your camera work, narration & the inclusion of issues in this difficult project. I believe this demonstrates your high intelligence & educational ability. Any student would be lucky to have you as an instructor. 👍
I totally agree!
You and Rustinox sure make a good case for the shaper. I definitely want one now. Thanks Ron
I loved reading your whiteboard. Always subtle. Thanks for sharing
Thank you for your authenticity in sharing this project! I so admire your abilities to adapt and overcome issues.
Impressed with you making your own broaches, had never thought about that before. Definitely subscribing to see what else you build in the future. Great stuff!
That was awesome. I admire your patience and commitment to this project.
Congratulations Jeremy, your persistence and make-do attitude are always inspiring and the end result is a complete success!
I'm pretty impressed by the homemade square broach! Well done...!
I love hearing the thoughts and mindset of kindred spirits. My first video of yours, and I thoroughly enjoyed it. Nice calming voice, and the patience of a cat. 👍🇿🇦
A mighty fine effort, Jeremy. As you point out there is a world of difference between theory and practice. You mastered both!
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.
So cool to see this and the video of Andy’s Machines doing it similarly but vertically with that internal cutter he made.
Great video! As always 😊
Very nice job. Hours of love went into that project.
That was a lot of effort and expertise. I'm blown away.
Your skills have elevated you above the realm of mortals. Well done Sir.
Nice job! I recently did a simple keyway broach, and then used what I learned doing that to make a backface borer. Seeing the same idea used to make custom spline shafts is really cool.
Great job! So fun to watch. This is really splendid workmanship! 🙌
Great stuff, I appreciate the subtle humor as well.
Remember, "Persistence is the bitter part of valor."
Flash back to age of empires 2…
I dread to think of the number of hours you put into this, but the results are very pleasing! I think a machinists jack might have been useful under the end of the workpiece on the shaper, it did seem to be deflecting a little.
@@tg5509 Where are your videos of you machining internal splines? Surely a real "expert"like yourself would want to show how it's done properly?
Great result, well done. Thanks for sharing and explaining the process. I have watched a lot of Rustinox videos. He explains things well and add a lot of humor. I find those shapers fascinating. I'm hoping that one will come up at a good price one day...
Meine Hochachtung für diese gute Arbeit.
I can watch your machines all day. Awesome videos guys.
Loved it. Yours is one of the most refreshing and honest machining channels out there. Love the seat-of-the-pants engineering, and the excellent result at the end. I would find making those parts way too intimidating, and put it off for years, so hats off to you for getting on with it. Keep on keeping on 👍
Very impressive spline work!
I work in an old school machine shop. Never made a broach, so I appreciate your efforts.
Excellent job on this. I hope you keep making videos.
Thank you! As an old fellow who's been around and seen a few things . . . I learned a few things and was entertained in the process! Thanks again. You have a new subscriber.
Спасибо что помогаете людям своим трудом механической обработки метала.
That was awesome to watch, you're a really skilled machinist.
You did a great job at making this look crazy simple. Incredible job! Great work! Thanks for sharing..
That's a freaking amount of time and effort you put into the project, thank you for the video. Subscribed.
I think I found my favourite machining channel. Awesome how you share your process: like this might be a failure but here's how well find out or run it out.
Excellent vid
Always inspiring to see someone engage brain and not give in... My projects are no where near the complexity of this one, but after watching this, I now know not to give in!
Liked that the build had a meaningful purpose. Great video
You've got some great skills and tools to put them to use - colour me very impressed!
I really enjoyed that video
Hi Jeremy, That was a really Tough Project, but you got it done. Hats off to you. After I get a new Lathe, a Shaper is going to be the Next Machine on my List. Great Job.👍
i like your sense of humor..
Seeing that i am not the only one, whose stuff flying around and never got found again , and also things just go wrong, get me a feeling, Not to be alone in a world, where people got hated by things.
Your skill at machining is amazing. You put all of the effort in your projects and they surely pay off! I still can't believe you just have 8k subscribers
8001 now
Very nice project.
You did an outstanding job.
Thanks for sharing.
Take care, EM.
Well as an amateur, I found this video absolutely fascinating. Thanks very much.
Loved it and it was kind of pleasing to see that I am not the only one to make mistakes.
One tip, always use cutting oil when threading whether taping, using a thread die or single point threading and when broaching.
Very good job !!! ...It is good to see someone that can do something with out a ""CNC"" and a stack of lap tops
Well done Jeremy the end result is top notch.
Excellent work! Very interesting and much enjoyed! Thanks for sharing.
Amazing job Jeremy.
Very interesting, like the broach making process, also small indexing head.
That part came out awesome Jeremy👍 I know for certain I couldn’t build that coupler….especially dealing with splines. You did a really good job there….something to be proud of🙂
That was a tough one....but you pulled it off...congrats, great job.
You did a great job on that project
Thanks for continuing to post great content.
Really impressive work.
Comically large, but awesome. Thats one for the books. Great that you are helping out. No good deed goes unpunished.
fantastic work, well done
Thanks for helping man. I live nearby. Crazy I stumbled onto your video. Very cool
Really enjoyed the content, Jeremy. Good job!
Nice job! People don't realize the obstacles you have to overcome in building, what seems to be, such a simple part.
Impressive work and patience!!!
10 out of 10 for persistence! Very impressive.👍
I have a machine that requires a splined receiver/coupling for a splined metric shaft. I can't believe how hard it has been to find one. You've made it look like child's play.. Great job!
Holy damn! This is really high quality content. Thanks for taking your time to show us.
Excellent real craftsmanship!!!! Awsome!!!
Sometimes the Recommended knows exactly what I’m in the mood to watch. This was very engaging, thank you. Subbed.
Fantastic work, very entertaining to watch.
Thanks for sharing this with us.
Your skill is highly commendable
You the man, nice work! Keep em comin! Enjoyed watching!
Amazing work man, I’m hobby machinist too but I could not have pulled that off, kudos to you.
Great job, I have always wanted to grab a shaper but am 100% out of room right now.
Well done Jeremy!
Nice job, and certainly an exercise in patience for you! sometimes the simplest looking part is quite complex to actually get made!
Thanks for sharing. Great work !
This is inspiring! Thank you for sharing!
Fascinating! I'm happy the algorithm suggested it.
That was excellent young man. 😊
That was very interesting and a very good job. I'm impressed!
Jeremy, a while back I had a similar problem with a splined shaft from a Volvo Penta transfer shaft. In my case, splines were worn due to hard shifting and the metal not being hard enough. So, I simply converted the splined shaft to a hexagon and that made the process much easier, not to mention harder to wear down. Great job. A pleasure to watch as always. Gilles
Your knowledge is very good.
Good job friend. Really good thorough work.
Awesome very nice work brother.
Hello Jeremy,
Nicely done... enjoyable viewing, thank you...
Take care.
Paul,,
I learned something new - when using setscrews to secure a hardened tool in a shaper, use at least TWO setscrews at 90 degrees to each other! The tool pressure is clearly immense. Machining a couple of mating dimples into the tool might also be useful (?). Great video. Many thanks!
That was fun, thanks for sharing this.
Don't put yourself down so much matey. It's awsome what your able to do.
Amazing video! Well done
Well done, all the skills
Excellent piece. I can almost feel the sinking feeling you get when you've put a ton of effort into something and it's not perfect. Seven attempts at a fit was well worth it. The only thing I'd have done different after all that work is to paint it bright orange and put LED lights around it!
Nice work
Great project and video DUDE!!
Thank you for helping out a community ski hill!
I have worked on alot of these submerged pumps and you've done a GREAT JOB making them fit together . The different companies intentionally made their connecting shafts different just so the average person couldn't connect them together they want everyone to buy a new pump and motor together but if you had the other two half's you could have just changed out the shaft witch is possible in some pump's or cut the shaft short turned down the end and pin or weld on the right shaft connecting head. But AWESOME JOB !!!