Broaching small items

[Andy CarruthersParticipant @andycarruthers33275]

I would appreciate advice on how to create a small ie 3mm x 3mm square hole in 1.6mm brass sheet please. More specifically, sample tools and techniques to do the job.

I would like to create "make-up" keys for Mortice locks, these have 7 segments for a 5 lever lock – I imagine a 3mm x 3mm steel bar which the brass sections ("bits&quot slide onto with a cap screw holding the segments together

Alignment is important as "bits" must not be offset from each other

Whilst "make-up" keys are available through the trade, they are expensive and the variety of locks ie 7 lever gun cabinet locks and some safes make it an expensive proposition buying any number of them

Your thoughts please

[Andy CarruthersParticipant @andycarruthers33275]

[Brian WoodParticipant @brianwood45127]

Hello Andy,

Use one of the square files from a good set of needle files and open out a drilled hole.

Regards Brian

[roy entwistleParticipant @royentwistle24699]

Should be no trouble with a three square file. If several holes must line up, make the holes in larger pieces first

Roy

[Andy CarruthersParticipant @andycarruthers33275]

Thank you – Occam's Razor I was over thinking the problem

[BizibilderParticipant @bizibilder]

https://www.youtube.com/watch?time_continue=1&v=MYI1slVGziU

Hopefully the above will help.

Edited By Bizibilder on 24/12/2017 10:32:19

[MWParticipant @mw27036]

Traditionally it would've been done with a series of steel cutting broaches with the edges gradually tapering towards a fully square profile.

[Gary WoodingParticipant @garywooding25363]

I'd use a piercing saw.

[Author]

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