That is a mighty key way cutter! “Holy High Speed Steel, Batman!” Big enough to play ‘Whack-a-Mole’ with the neighborhood kids when they cut across your yard!

Adam - I very much appreciate the time and effort you clearly put into your videos. Your videos are coherent, informative and very pleasant to watch. Again, thanks, this one is another good one.

I am a retired mechanical engineer worked in helical speed reducer manufacturer in india for nearly 50 years.it is very interesting to look in to your video. Nice .Thank you sirs.

installing a broach plug with a crane.. I'm still laughing. incredible. enjoyed!

His Broach shaft brings all the boys to the yard....and damn right, they bigger than yours...He can press em' but he gonna have to charge. Seriously though, as a Guy just getting into machining with a cheap craigslist special lathe...I really appreciate these videos.

0:45 One of the most satisfying things iv ever seen. I love machining!!! Thanks for the videos Adam!!!

Really great to see that type of job done on the tube. You are the man, thanks for sharing.

It is a treat to watch beautiful machine work being done.

Amazing job Adam , I enjoy your video,s . I always learn something from watching . Thanks

This kind of stuff is completely fascinating to me. I love it all!

Cool work, Adam. Thank you for sharing it, appreciate.

Fine and precisely done. Bravo Dave! Thank you. - Was Dave macht, läßt einen immer wieder erfreuen. Wenn ich mal keine Lust habe, schau ich ihm einfach eine Weile zu, dann kommt Freude auf und ich habe wieder Lust, das Angefangene in meiner "Huddelbud" zu Ende zu bringen. Dabei fällt mir ein, daß ich die Dampfzylinder neu machen muß, weil die ersten Lunker im Guß hatten. Jetzt sind sie GGG und Standard "oldicht" - Flächen sind bearbeitet, jetzt heißt es Grenzmaß-Vorbohrer einsetzen, ca. vierzig Löcher vorbohren, gewinden (Gott sei Dank hab ich einen Tapmatik). dann Stehbolzen fertigen und einziehen - aber vorher noch die Zylinderlaufflächen mit dem Wohlhaupter ausdrehen und honen.... Los geht's! ;-) Dann fang' mer gleich an ...

nice work Adam , always a pleasure to watch your videos

An excellent trio of videos today. I especially appreciate the tribute you continue to pay your dad and grandfather at the conclusion of each video. A real class act!

holy moly! fantastic work Adam. Really enjoy your videos!

Hey Adam that is some heavy duty broaching young man great job as usual !!

Thanks Adam I really enjoyed those huge honking Monster-Big-Boy Broaches, great stuff for video, for sure you don't see that everyday.

Okay. I had no idea what the broach was for until I saw the footage of it below the press covered in chips. I thought it was the. Square pin that kept the gear assembly from freespinning on its shaft only to discover the broach cuts the channel in the gear for that pin. I really enjoy watching your subconscious or automatic mastery in action. Case in point is how you ensured the lift sling for the plug was under even tension before attempting to lift the plug out of the assembly. You do it from years of practice in this area of artistry where others, who are less adept, would fail to even the tension and jam the plug at a cant. Again, another excellent video demonstrating the skills needed to be a MASTER machinist. I should likely point out that I know NOTHING about how to do what you're doing nor do I have even the simplest of operational knowledge for the tools you use, but the way you present it makes it seem as if I could walk in and, with a half-day of instruction, do what you do. Nothing would be further from the truth. It takes YEARS to get as good at this as you are and I appreciate the time you take to demonstrate one of the right ways to do this work.

Man , That is some ABOM broaching .. Never saw such tooling before !!

I was going to say that I won't even ask what those broaches cost but I was beat to it. I also was going to say it looked like a job for a shaper but was beat to that too. I've made some custom broach bushings in my day for special jobs but never saw anything as large as those, or even a press as large as that. That customer must have really deep pockets. Wow am I ever impressed!

Great series Adam, I did a lot of work with those huge gears, but i always liked watching the machine processes done by top notch skilled workers. Your skills have my greatest respect, a thumbs up seems too small an acknowledgement to you. Cheers!

Really enjoy your vids. You are what 'skilled trade' means brother!!

Another advantage to the vertical shaper is that for less than $500 a job shop can have all the tooling they need to cut every internal keyway they would ever think of cutting from 1" on up and that even covers all the metric sizes also. We have an old Davis Keyseater to cover all the stuff below 1" which comes in handy when you are in a old school job shop that does something different everyday.

I just broached a 3/16 keyway in a small gear for a buddy's lathe with my arbor press. Then I see this monster getting pushed thru. WOW. Glad you didn't have to use an arbor press!!!!! I couldn't believe you let it fall. I cringed pretty hard!

nice work man .pushing 5 1/2 inches a minute at 20 tons on that press is still faster than my manual press at half the load !

That's incredible. It must be an absolutely enormous piece of equipment that the Kop-flex shaft-coupling fits into.

Hello Adam beau travail !! toujours un plaisir de te voir usiner .. merci beaucoup !! From france // yves

We've got a pump at work from that same company. Runs on 480V 3 phase, 20 amps. 20 tons is a cake walk for it.

Thanks for the video Adam 👍

good work as ever adam that gear is massive

Adam, the video's just get better, keep on trucking big chap!!!! Joe.

Takes me back to the bad old days when we had to chomp out big keyways with a 48" Rockford vertical shaper working side to side with a. gap tooth tool. PITA. Broaching seems so much more civilized. Easier size control and better finishes to boot.

I have an engineering company close to my factory and they machined huge gears and train wheels like those you showed. Some of those gears are as big in diameter as a man. I am told they are mining gears. Anyway sadly that business shut down a few months ago and the machines coming out of that factory are so big it makes your jaw drop open. Anyway its sad to see such a company have to let go. Would be some great men in that factory, and not many who can work those machines.

grosse Teile und 100% Passgenauigkeit, Respekt man!!!

Hey Adam, Another great video! That is a serious (Abom size) broach you have there. I know I have told you before but I feel it needs said again. Thanks for all of the time and effort you put in to these videos. I'm not sure all of your subscribers realize the hours you put into shooting and editing these videos for us to enjoy and learn from. So thanks a lot man, I can't wait for the next one. Gary

Top notch Engineer, top notch video, thank you.

That's cute! So tiny! Works the same as the big broach machines. Fastest way to remove metal from a part.

Love that trolley set up!

big, bigger, biggest and Abom size! Thanks for sharing!

Hi Adam I'm a long retired machinist from a small town called Hartlepool in north east England. I've recently been watching lots of your excellent videos' and I'm fascinated by how similar our working methods and terminology is considering being on different continents etc. Regarding this particular project I would ask if you considered a suitably sized slotting m/c. I've machined internal keyways in hundreds of similar sized gear wheels with ease using various slotting m/c s'. I'm sure you could acquire a used m/c for very little outlay, once you have a slotter virtually no ongoing costs for expensive broaching tools, also job done in fraction of the time. Anyway It's just a thought, keep up the brilliant videos Best of luck Dave Johnson

Awesome work.

Great work Adam!

thanks adam! very nice videos this week too!

Adam, when a have a press that is not big enough to run your broach efficiently, you can help it by using 1/2 the shim thickness each pass, it will take more passes but it will be easier on the press and about the same time. You have a nice boring mill, you should build a 4 poster press in your shop. it's not hard to do. It is a good bit of money for the materials and most for the hydraulic system(which you can also build),, We even built our own hydraulic cylinder, 8" bore, you will have to farm out the honing of the cylinder, but the rest you do yourself. But once you have it up and operating, it will pay for itself in no time plus it will make life a lot easier. If you interested, I can help you with the details. We built our own press and it would push about 100 ton with the pump set a max at 5000 psi( we usually did not need to run it at that pressure, but it was there if you needed it). You must also be aware that a broach has a limit on how thick a part you can broach. If you push too big a chip there is not enough gullet space in the broach to take all that chip, and you will either break an expensive broach or you will jam up the broach in the part. You can do longer parts, but you must use thinner shims to allow the broach to make a pass without over filling the gullet in the broach. My family and I had a very good job shop, my father was the finest machinist/engineer I have ever worked with!! Sorry to take up so much space.

Abom clockmaking XXL ;-) Very enjoyable video as always - thank you very much for sharing your knowledge and experience Kind regards from Germany Harald

looking at the size of the top of the steady rest on that lathe, it looks like you need a crane just to open or close that too. nice work Adam. thanks for sharing.

We used to use Kop-Flex Couplings between compressor and turbine/gearbox on Test Stand at Dresser-Rand. Different application, but god awful expensive. Blow the hubs on via Enerpac pumps. Fun times.

great video thanks for taking the time

That was just freakin awesome!

Amazing the clearance between the cutting teeth is enough to catch all the steel shavings without binding the broach. Must be a bigger gap than what it appears to be.

That's a heck of a keyway.

That is one heck of a broach

Damn you’ve lost heaps of weight nice work mate good job!!! Now you can make these amazing videos for an extra 30 years haha

Hey Adam You get to play with all the big toys . Great video.

Combining the shims, you reinvented the binary system. :)

هنيالكم يا عمي على هالعلم والتكنلوجيا چا احنا واحد يكتل الثاني . هنيالكم يا عمي .

Adam, They were some serious broaches.

lol, that 2" broach is just silly. Thanks for three vids this weekend Adam!!! :-D

Looked like some fun and heavy work just to make the bushing and shim. Nice having that hydraulic pump on that thing. It would have been a lot of arm pumping on my little Harbor Freight press that is still in the box.

I consider buying the movie version of this series!

Damn Adam that's what I call a broach, never seen one you had to handle with a hoist also that's one nice press.

Great work!

really cool stuff man.

My dad worked for Kop flex In maryland back when that shop was open. he would have made that coupling

GREAT VIDEO !!!

Great videos

Nice video Adam, always look forward to Saturday & Abom79.

Gives new meaning to the term; "Give em the gears"! lol

That 2 incher a monster ! LOL

Nice job Adam! Never used a crane at all, and even never saw a wireless one in person :-P

When I was in the army we had a gear like the big one at the end of your video delivered to our motor pool. Don't know what it was too but definitely wasn't the hummer CV axel that the label said it was.

Adam You need your works to get a slotter if they get many more of those to do. Great video skills as well as workshop skills And I thought a 3mm broach is big 😎 well it is for me as I use 10BA screws Stuart

well that was awesome, haha I thought those gears at the end were on a table, sure fooled me

Thanks for sharing it all with us. Don't be affraid I will copy you.......

Man those gears were HUGE at the end!

Good lord - that's one big broach. Wow...

Hi Adam, nice video, as always. Please have either some chainmail (hanging from the top of the press and weighted down) or polycarbonate plates between you and the punch, especially when using additional bars. I have seen them fly across the workshop and embed themselves in concrete walls if they do not line up perfectly or get stuck when pressing things out. I am no big fan of being afraid of everything that might happen by a remote chance, like some health and safety guys are, but this kind of accident is common enough that you should protect yourself and your coworkers against. It takes little effort and makes a huge difference.

you guys need a slotted to do the key ways so much faster and easyer, and that is about the size of some of the gears I make they are easy the small ones are the hard ones thanks james

great video. i really like the extendable table on the otc press. give us a tour of the press some day. just curious did you see the price of the broaches?

Хорошая работа!

I was wondering at first who was catching your broach good job.

I would like to see a walk around your press I need to change my and maybe get some idea from yours Thanks

Amazing. Thank you!

Would be nice to see a picture of the whole machanism when the thing is complete assambled. Nice work ;)

Спасибо за видео! все очень интересно и в больших размерах !

So I take it timing isn't critical? How would you time the key to a tooth if you had to?

So I was going to ask what keeps the shims from being pushed thru but I imagine that the tapered pressure must be greater and that wedges it in.

I have been reading some of the comments on this and Abom79 did what he had to do in the shop he is at to get these parts out quick. That being said, if you are going to be doing some more of these over time a vertical shaper is the only way to go. The shop I work in could have done both of these for $680 or less each. Also, with the vertical shaper you have the ability to get any fit on the key your customer might want from interference fit to loose with ease. You can also get some fine looking finishes in the keyway also. To cut a 1.5" or 2" internal keyway you do not need to have that size cutter, just step it out, that way you can have a roughing pass or passes and a finish pass to the fit your customer desires.

This is just sick.... Even for you :)

Never installed a broach plug with a crane, but I have run a CNC horizontal mill that enclosed the operator rather than the workpiece.

Really slick idea, machining a flat on the plugs to measure from. Also have never seen the "roll out" feature on the press beams. Do those handles have an eccentric that just slightly lifts the beams off the stops on the sides to roll it out? From the angle of the sun, looks like you were getting into overtime mode on that job.....Dave

Wow, great camera placement .

hey have you done a video on what types or brands of oils you use at home for your shop? I'm curious to see what you use and why you chose those over others

Cool stuff Adam! I have the same press but the 100 ton version by OTC. Don't know what I'd do with out it!

Nice work Adam , Go big or go Home , Ha Ha !

I enjoy watching and wondering how you are going to cut.

Your a heck ova man adam

Great video, as always Adam. Those couplings are not watch fobs.

Did the shop fab the slide out hydraulic press table?

Wonderful video. Question: if the customer is charged for the special tooling, does the customer own the tooling after the job is completed?