Best way to cut a keyway in a hub?

[Reno Speedster]

I have an original set of Dayton wheels and hubs but one of the rear hubs has a bad bore and keyway. I have looked for another, but so far no luck. I am getting ready to machine a new hub, which is work, but not really hard. The challenging part for me is broaching the keyway in the hub. I would need to make some special tooling and jigs and I don’t think my hydraulic press is stable enough to do the job). If you have done this job before, I would love to know how. Alternatively, does anyone know of a shop or person who I can get to do the job?

[Jerry VanOoteghem]

This is something I would hire out to a machine shop that specializes in cutting keyways. I'm not sure Alaska would have many of these shops however.

Here is one such shop near me, (not much of a website...).

http://centralslotter.com/

Another: https://superiormetalfinishingdetroit.c ... g-machine/

A wire EDM shop could do it as well, but I'm not always impressed by the skill level of machinists that do wire EDM work.

[ModelTSpeedster]

Try contacting Jack Putnam. I bought one of his newly machined Dayton pin drive rear hubs and it was perfect.

[Craig Leach]

If the taper can be saved by lapping it to an old axle then the keyway can be filed out with modified square files, then mill a stepped key to fit?
Craig.

[Reno Speedster]

Graig, the bore was monkeyed with in an attempt to “restore” it and is not save-able without welding and then I would have to do the machining anyway. I would rather start from scratch and have a hub I know is good.

[Reno Speedster]

Try contacting Jack Putnam. I bought one of his newly machined Dayton pin drive rear hubs and it was perfect.

I don’t think they are still available. Jack offered me some raw castings, but I would still have to do the machining.

[Kevin Pharis]

For every .001” of diametral wear (or machining error) in the taper, the hub will move along the axle about .009”. A little wear can ruin a hub quick!

The keyway is a challenge no matter how you do it! I had no luck with multi tooth broaches with my steel hubs. Might work better if only enlarging a worn keyway in an iron hub tho…? Nothin wrong with stepped keys

[Dan McEachern]

A shop with a keyseater or slotter would be best. A Davis would be best because the small end of the taper requires a small broach bar and you run out of room quickly. You could cut it yourself using a boring bar in a lathe and drag cutting it, but you would have to kick the hub over at the taper angle- make some wedges and clamp the hub flange on a faceplate. Time consuming but if you only have 1 to do.......... As Kevin mentioned, the bore is too long for a short push broach to work. A good wire EDM guy could do a nice job, but wire guys are usually $$$.

[RecklessKelly]

You could make a broach bushing out of an old tapered shaft end with a stopper shoulder screwed on, mill the slot to fit a broach, which McMaster or MSC should have. Just need a press to drive the broach in.

[Cordes_jeff]

I have a reciprocating key cutter that I have never used. It came with a number of broaches for various size key ways. I always thought it would be useful in this type of situation.

[Allan]

Many Hayes rear wire wheels have flogged keyways. I get around this by boring them out and pressing in a machined down centre of Ford hub with a good keyway.

Allan from down under.

[Reno Speedster]

Allan,
That has been done on one of my original hubs, if making a new hub does not work, I will give that a try. I think with some pins and some stud and bearing mount. That would work fine.

[Allan]

Once I have pressed in the replacement hub centre, I drill and tap a hole on each end to take a scotch screw to prevent the two components moving. I believe you guys have a different name for scotch screws.

Allan from down under.

[Jerry VanOoteghem]

Once I have pressed in the replacement hub centre, I drill and tap a hole on each end to take a scotch screw to prevent the two components moving. I believe you guys have a different name for scotch screws.

Allan from down under.

Inour shop we've always called them "Dutchman".

[Allan]

Dutchmen, Scotsmen, both with a reputation for being a little tight.
Allan from down under.