The BAD AST Project - Faze II

[astroracer]

I tried using an Allen key to broach the driver hole but it just wouldn't do a clean job. It kept galling as it was pushed in. The Torx driver works great for some reason. I don't really care what it is as long as it works.
I got the threaded rod and made a couple of plugs tonight. Went as easy as I was hoping. The Torx driver pushed in just as easy as it did with the aluminum test piece. I'm happy.
I got a foot of the 3/8-24 rod and used about half of this piece I cut off...

Dilled a pilot hole and ran a 90 degree chamfering tool into the drilled hole to make the bevel.

The beveled hole.

For the broaching job, I drilled the hole out to .173 dia. That is the one I used in the aluminum piece.

I ran the fitting into a 3/8-24 nut so I could get the "broach" tapped in straight.

Just a couple of light taps with hammer got the broach started.

I then clamped the assembly into the vise and pressed away...

Didn't take much to do the job.

I ran one into the prop valve.

And checked the clearance. We are good to go.


I made a couple of them while I was doing it. Now that I've made one the whole process only takes about 10 minutes.

Now, on to bigger and better things!
Mark