Axle Slot Cutting (K House Groove)

[GravityX]

I was playing around tonight trying to cut a better K House groove and came up with this technique. The result was a nice clean deep groove. So, now the screwdriver will not jump out of the groove creating a torn up axle head.

Here is the setup...

...and here are the results.

 

[cygnus]

Hey thanks for the setup pic. It looks a lot easier than fee hand.

 

[3phase]

Gravity.....would it not be possible to do the k house groove on your mill? Are the axles heads to small or they don't make a mill end that size ?

 

[GravityX]

Gravity.....would it not be possible to do the k house groove on your mill? Are the axles heads to small or they don't make a mill end that size ?

I'm sure there are end mill bits small enough to cut a groove of this size, but this is what I had on hand without spending any money to buy a miniature bit.

 

[3phase]

Budget constrictions. I totally understand.

Didn't know if it was just more difficult with the mill. It would be nice to line up four or more and take care of it one swoop.

 

[DEW36]

I was playing around tonight trying to cut a better K House groove and came up with this technique. The result was a nice clean deep groove. So, now the screwdriver will not jump out of the groove creating a torn up axle head.

Here is the setup...

...and here are the results.

This is really cool!! I had to cut my groove a little deeper too so I could use the screwdriver again, but mine doesn't look as good as yours.

 

[HurriCrane Racing]

This puts my mini miter box and hack saw to shame!

 

[Kinser Racing]

Looks awesome! Mine look like that but with a smaller groove. /images/boards/smilies/thumb.gif

 

[bracketracer]

Cool setup Paul!

You could substitute a slitting saw if you needed a narrower groove.

 

[Guest]

Those look perfect!

Thanks for the tip!

 

[IAE Racing]

Looks great Paul! Tool envy kickin in. LOL

 

[GravityX]

Cool setup Paul!

You could substitute a slitting saw if you needed a narrower groove.

Thanks for the idea Stephen! I'll need to look into that.

 

[quadad]

I have been using slitting saws in the 0.014" - 0.016" range with the axle "chucked" into a block in my X-Y vise. That way I am able to control depth of cut and cut across the axle. Once set up, they all get cut in the middle. I know it's overkill, but if you buy a bunch of axles at one time, it pays off. If you only have to slot one set of axles at a time, then it's probably not worth the setup time and you are better off with the small miter box. I have both setups.

BTW, I am not using a regular screw driver. The size I mentioned is for using more like a eyeglass screwdriver from a precision screw driver set.

 

[GravityX]

I have been using slitting saws in the 0.014" - 0.016" range with the axle "chucked" into a block in my X-Y vise. That way I am able to control depth of cut and cut across the axle. Once set up, they all get cut in the middle. I know it's overkill, but if you buy a bunch of axles at one time, it pays off. If you only have to slot one set of axles at a time, then it's probably not worth the setup time and you are better off with the small miter box. I have both setups.

BTW, I am not using a regular screw driver. The size I mentioned is for using more like a eyeglass screwdriver from a precision screw driver set.

Can I get a picture of your setup. I'm looking for a setup with an 1/8" arbor to fit the collet I'm using.

 

[quadad]

Yes, but I have to find one first ...

 

[Papa V Racing]

GX- Great tip for the K-Grooves.... I have also gone to a smaller head screw driver to get into the groove..

 

[LightninBoy]

I was playing around tonight trying to cut a better K House groove and came up with this technique. The result was a nice clean deep groove. So, now the screwdriver will not jump out of the groove creating a torn up axle head.

Here is the setup...

That's almost exactly what I do, though my tools aren't as sophisticated. I use a Dremel and Dremel workstation, positioned vertically just as you have. To hold the axle, I ... uh ...

<looks both ways>

use

<leans in to whisper>

the DW axle straightener tool and a small clamp to squeeze it tight.

I rest that on the dremel workstation table and slide it gently into the spinning cutting wheel. The biggest challenge is setting the correct height with the Dremel workstation to get a groove in the center of the axle head because the workstation moves the Dremel up slightly when I tighten the position.

Anyways, the main point is that the concept you showed is solid and can be achieved with a variety of tools.

 

[zeebzob]

Gravity.....would it not be possible to do the k house groove on your mill? Are the axles heads to small or they don't make a mill end that size ?

I use a small end mill, but its still not as thin of a slot as Paul is getting. There is some play as the slot is wider than the screwdriver, but it still works well. I have tried smaller end mills, but they end up breaking very easily.
I like Pauls method better, I am going to give it a try.

 

[Crash Enburn]

To hold the axle, I ... uh ...
<looks both ways>
use
<leans in to whisper>
the DW axle straightener tool

So do I. The tool gives me a nice reference line to use when I manually line up the cutting wheel of the Dremel to the center of the head.

 

[GravityX]

Anyways, the main point is that the concept you showed is solid and can be achieved with a variety of tools.

Oh... I agree! I was just looking for an easier method than what I was currently employing. This is what I came up with what I had on hand. Works better than my previous method, by this I mean it saves me time.

Be on the look out, I'll have that tool I previously used for sale soon along with a few other items. Stay tuned.