Making Spline Shafts For a GEARBOX (Internal Splines too)

G'day everyone,

One thing that I always assumed was out of the question in terms of being able to make in my home workshop would be an internal spline shaft. External splines could be done (although probably not involute) but internal splines requires sophisticated pull broaches.

However when push comes to shove, and I need a spline shaft, well I had to figure out how to make one.

The spline shaft that I make here is a 6 sided, straight faced spline. This one in particulate does not adhere to iso standards, but with slight modification, I can see this being used to broach one that does.

I do want to point out here this this is a hobby focused video. Broaching 6 keys took a very long time, and I wouldn't expect a job shop to use this, but its always handy to know this method.

I hope you enjoy the video.

#machining #splineshafts

Timestamps
0:00 - Intro
3:32 - Internal Spline Broaching
5:32 - External Spline Machining

[edwardhugus]

A great straightforward approach to the problem. As soon as you cut the keyway my brain went "Of course! The answer is NOW obvious!"

[bsppirate]

As a someone who is a machinist and gear cutting specialist I always love watching how people come up with their methods of making their desired gear(s) in their home shop. You're bang on by the way, majority off the time spline shafts are hobbed/shaped and internal splines are pretty much always shaped unless it has a non standard pitch which will lead to it being wire cut

[thepagan]

Nicely done. We built industrial gearboxes and supplied gears to customers specification, mostly automotive. We broached, hobbled and shaped splines, but when doing single piece for gearboxes we used the same method as you have shown. We did, at least once, have a special single cut broach made so we were able to cut 6 splines with a rounded root. Your way works great so kudos to you. Thanks for posting ✔️👍

[dougmorgan]

You keep coming up with solutions to problems I didn't know I had. Thank you.

[ourtube]

The problem solving and creativity always amazes me. You do a great job of reducing things into the simplest operations and tackling them one at a time.

[Hallacairion]

As a trained machinist, we make splineshafts pretty much in the same was, just that we use a flat cutter on the side so the splines are in a horizontal position when being cut and we use a formtool specifically ground for the job to make a round profile at the foot of the splines.

[HexenzirkelZuluhed]

You're doing the hackiest yet coolest DIY machining anywhere!

[thomasstone]

For a "hobby" workshop that is a superb result. Nice one!

[LittleAussieRockets]

That was a great result. Not only was your method straightforward It is also very repeatable. Good stuff 👍

[ZappyOh]

I'm so looking forward to hobby-shop-affordable metal 3D-printing :)

[ericmueller]

The well placed gear box pun was superb.

[belatoth]

Being AM and CEE my two favorite channels I consider learning Australian language :)

[fytmjgc]

It seems you will have accumulated error with that indexing technique, but for only 6 splines probably good enough. I made an indexing plate that attached to the end of the shaft. It has the same number of holes as splines, and uses pins in the holes resting on an adjustable parallel. I learned that from JoePie, he has a great old video on it.

[billmacfarlane]

Wow! Timely! I'm just been trying to figure out how to cut an internal spline in the clutch hub of a speedway mororbike. Your broaching method should do the trick!

[bulletproofpepper]

That is amazing! I’m a hobby machinist and I also love 3D printing. This will solve so many problems with trying to print 3D parts to use in the machinist shop made tooling. Herringbone 3D printed gear teeth are reasonably strong the weak point was always the one or two key way(s). I like the simplified profile of your 6 way shaft. I had over complicated the ways of my design for years and turned it into unitanium with to many stress risers. Thanks for sharing.

[Festivejelly]

Very nice! Looked like a great fit there.

[Anon_Omis]

This is a brilliant solution I doubt I'd ever think of.

[kioliex]

Great work. Before seing this video I was think of doing something similar for a restoration project. Now I am possitive that it is the way to go.

[gregc]

Hi
I just followed your instructions, no on and off settings But the beeps are ON So happy for your advice.
Thankyou so much 👍👍👍
Stay safe
Regards
Greg

[swamppifi]

A simple solution to a complex done....