slotting

As part of my CNC Lathe build, I need to install some pulleys on the spindle drive. The easiest method for making a key way in a pulley is to broach the feature into to part. I'm facing two challenges in using this traditional method: no arbor press and no broach tooling. O.k., alternative...

I have a few blades I want to enlarge the center hole, they are 3-1/2 to 5" steel blades 3/32" thick . I have a few ideas on how to go about it . Can anyone that has done it with relative success give any thought on doing this ? I know if the enlarged hole is not dead center then I...

On an upcoming project I need to make a 1.5" long slot in a 1.5" thick hunk of 6061 aluminum. The bad news is I don't have the tooling yet for slotting. The slot will be 3/16 wide x 1.5" long and 1.5" deep. Ideas I have come up with are to use a sawzall with some kind of a Rube Goldberg guide...