Milling and sanding to make a key fitting the keyseat and keyway …
↓↓↓ Complete description, time index and links below ↓↓↓

In the previous video we’ve made the last large component: the backplate (link below). Now there’re only three small parts left to do. Key amongst them is, well, the key, which goes into the shaft’s keyseat and the wheel hub’s keyway.

First we saw off a piece of aluminum stock and mill it to length. Then we mill it to the required width. After that we mill it height wise into a wedge, fitting the odd profile of our keyway (link below). Finally sand the whole thing until it fits.

00:00 Intro – fabricating the key will be a challenge
00:39 Drawing – shows a rectangular block, but it isn’t
04:12 Sawing – off a piece of aluminum stock
04:34 Milling (1) – one end square
04:56 Milling (2) – the other end square and to dimension
07:16 Milling (3) – 1st side square
08:51 Milling (4) – 2nd side square and to dimension
10:54 Milling (5) – 3rd side into a wedge
13:25 Sanding – the key to fit into keyseat and keyway
15:23 Result – a nice and tight fitting key
16:37 Wrap-up – next are the two stop bolts, bye

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