So I want to make a keyway..

It does not take as long to cut a key way in aluminum in the lathe as you may think. It goes pretty fast. Don't overshoot. This could also be done on the BP.

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Robert
 
Worst case is to use a multi-blade hacksaw to rough it in and then clean up with a small file. I didn't like it either when I had to do it. But, in aluminium, it isn't hard. The best bet is to acquire the broach. A shaper, if you want one. But it should be as a generic tool, not just cutting keyways.

It's all about time and money. The only advantage to using hacksaw blades and a file is it's available "right now!" and it's cheap. But otherwise, a PITA.

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