if you wanna use a press you'd be well advised to first make this press die.
it's used with a press to give support for the rim instead of just hoping it'll clear.
the inside i.d. is just a smudge bigger than the axle o.d.
i used 1" thick alumiinum stock and cut it out a disk with a 3" hole saw.
unless you want to spend a long time cutting be sure your i.d of the hole saw just clears the edge of the material.
the idea is to let the chips have somewhere to go other than the bottom of the hole.
done right a regular hole saw takes about one minute to cut through.
in the pix below you can see how the actual saw part went over air on part of the aluminum that is deliberate to give chip waste an exit out of the cut.
after you get a disk take a 1" hole saw and cut a circle in the middle using the same hole saw center guide hole.
you only need a story line at first maybe 1/8" deep.
then take a twist drill and drill your keyway hole on the edge of the story line so 3/4 of the hole is outside the story line in the die itself.
THEN cut the 1" hole the twist drill hole gives your chips and escape spot and somewhere to fall out of the hole saw.
i use a squirt bottle of cut oil to keep things lubed.
after you get the inside hole use a small file to remove material at edge of hole for axle key.
also good idea to knock off all the sharp edges.
this is what you're aiming to make sorry about lame pix.
if it's a margay 150 axle and true i'd try to save the axle too.
they are some of the best axles made.
all you have to do to use same press die is cut it in half so you have two u shapes.
DO NOT CUT IN THE KEYWAY but about 90 degrees out from it.
put around axle and use a hose clamp to hold it together.
dave
Last edited on Mon Jun 11th, 2012 02:34 am by David Luciani
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