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We manufacture rotary broach tools and I know what you mean about cost. However, the cost of business these days requires these prices to cover all the expenses. You mentioned the material, manufacturing, equipment, etc. and there's also the quality systems to insure consistency, packaging etc...

Beautiful work.

Jeroen, you've done some beautiful work I agree! Thanks for trying out our rotary broaches and let me know if you have any other questions. Even though our broach holders are for production shops, we were very interested in your results. If you ever bump production up to 1000 parts per year let...

Chitown, the key (as noted by rhankey) is that the broach is held at an angle. Interestingly, the rotary broach tool will also work in a mill, where the part is stationary. In the mill, the rotary broach holder is turning and moving the broach in an orbital motion while keeing the form on...

I agree, nice work, and the pics are wonderful.

Ken, that's a fantastic explanation of rotary broaching. I'd also like to point out that the same tool works in a mill. This is a 'no float' holder. http://www.youtube.com/watch?v=uTsPXFy7Xx0

Some hole prep tips:

Nice sketch, keep us up to date on your progress.

Great video too.

Another option is renting the tool instead of buying. Polygon Solutions offers broach holder rentals if cost is an issue.

I think they were on 23 Mile road. I see you are in Sterling Heights, so you're not too far away from there. We used to get some great plant tours, and I remember getting some great engines to mess with, and Lionel's war era history is very interesting. We had some fishing reels they made back...

I am way too impressed. I love it.

My dad worked at Lionel trains while I was growing up, giving me a great start in exploring mechanical devices. I used to repair bicycles in my neighborhood, and was experimenting with multiple cranks when I went full bore into drafting/engineering. Hope to get back to my roots soon.

Blind holes are no problem, except there needs to be room in the bottom of the hole for chips. This holder has a hole that runs through the center of the broach and then ports out the side of the body so that any air, cutting oil, or coolant that gets trapped can escape. You can broach a wide...

I saw a post here about EDMing some holes in a custom made wrench. Here's another way to do it using a rotary broach tool holder. Rotary broaches can be made as a hex, square, spline, etc. http://www.youtube.com/watch?v=uTsPXFy7Xx0

Hello model engine makers. I work at a cutting tool shop, and love to look around at what everyone is making. It's good to see online that the art of making engines, model trains, and other historically important metalworking isn't gone. I've never built one myself (yet), but hope to offer some...