saber saw keyway cutting

[Frank S]

Totally the wrong tool for the job, but I found myself not having anything small enough to cut a keyway with in a 5/8" bore other than to cut them entirely with a file. I clamped the foot of my saber saw in a vice then used it like a die filer to rough cut the small keyways in several sprockets then finished them off with a file it really saved a lot of arm motion.

[Unkle Fuzzy]

My machine shop teacher told me that there no wrong way to do a job. There are better ways, but no such thing as a wrong way.

[WmRMeyers]

My machine shop teacher told me that there no wrong way to do a job. There are better ways, but no such thing as a wrong way.

So long as when the job is done, you still have all your body parts properly attached, and all your blood is still inside your body where it belongs.

[mwmkravchenko]

This I have done. Necessity makes for ingenuity.

[nova_robotics]

I don't have a shaper and may have to steal this at some point. Well done, sir.

[Frank S]

I don't have a shaper and may have to steal this at some point. Well done, sir.

My dewalt saber saw is variable speed so I could go as slow as I felt necessary. Holding the small sprocket by hand can get dicey fast so if you use this idea I recommend a plate with a slot in it so the part you are cutting has a full bearing surface to rest on.
be safe

[Christophe Mineau]

Could be fun if you could also adapt a needle file to fit the sabre saw jaws, maybe with some kind of support at the other end...

[DIYer]

Thanks Frank S! We've added your Keyway Cutting Tool to our Metalworking category,
as well as to your builder page: Frank S's Homemade Tools. Your receipt:

Keyway Cutting Tool by Frank S

tags: keyway, cutting tool

[mklotz]

Could be fun if you could also adapt a needle file to fit the sabre saw jaws, maybe with some kind of support at the other end...

Jigsaw blades cut on the pull stroke while needle files cut on the push stroke. This means that needle files must be mounted upside down in the jigsaw. You can see at least one way of doing it in my miniature die filer article...

Miniature die filer

[Dry Creek Smithing]

Frank, Nicely done! Yes, I agree necessity does have a way of making us think outside of the box sometimes. Well done.