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For fans of Frank Ford's site, here I basically copy his technique for making a broach:
Start with a broken endmill from the scrap-HSS bin. You guys do save this kind of thing, right?





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Information contained in these pages is for reference and entertainment purposes only.  Our methods are not always the best,
quickest, safest, or even the correct ones. It's up to you to know how to use your own machines and tools.
Keep your fingers away from the spinny blades o' death and you should be all right.