How do I do this?

[dallen]

depending on how many of these bushing that there are for you to have to make, it may be worthwhile to have a broach made so that you can cut both sides at one time.

if it is a job that will only be a couple of them at one time, or one once in a while I would set up and figure out how to drill the thru hole then use an endmill to open a slot in the end for the drive stud to fit into. a lot less work that way.

[Mayhem]

Just out of curiosity, what exactly does this mate with? I'm wondering if it needs to me metal or could be made from an acrylic or plastic etc.

[PixMan]

A broach made to cut both sides at once is easier to make. However, I believe the force required to push it through the hole would be far too great.

[stevec]

Looking further at the photo makes me wonder, are the flats the full length of the bore? If they are do they have to be? If a smaller length of the "keyed" portion would work, say, 6-7mm it could be done with a file.

[Wongster]

Hi guys,thank you for your suggestion. I don't think I'm ready to make a broach. Heat treating and hardening are skills that I've yet to learn. I may just drill thought and finish the 1mm odd thickness by a file.

The material in use has to be 304 SS as it will be submerged in a drinks dispenser. I've not have the chance to see the bushing in use but was told that it is inserted in a motor shaft with flats at the end. I don't have time to visit my dad's office though I would very much love to - there is a machine shop next door...

The making of the bushing will be ongoing though the quantity is unlikely to be big. For this model of the dispensing machines, he only need 3 for a start.

Regards,
Wong