How can I broach a 7/8" square hole in a 3" diameter blind flange inexpensively
I have a small job coming in the shop in a couple days and I don't have the proper size broach to do the job. And, the job isn't big enough to warrant buying a new or even a used 7/8" square broach (even if a good used one could be found). I have 6 of these square holes to broach and I believe the flanges are carbon steel. The tolerances are reasonable as I believe they are simply square drive holes.
One idea is to drill holes then square the corners with a jig saw or scroll saw, then finish with files. Another is to drill the holes then mill them square with a 3/16" end mill, then file the corners square.
How would you do it if you didn't have a 7/8" square broach?
I have a small job coming in the shop in a couple days and I don't have the proper size broach to do the job. And, the job isn't big enough to warrant buying a new or even a used 7/8" square broach (even if a good used one could be found). I have 6 of these square holes to broach and I believe the flanges are carbon steel. The tolerances are reasonable as I believe they are simply square drive holes.
One idea is to drill holes then square the corners with a jig saw or scroll saw, then finish with files. Another is to drill the holes then mill them square with a 3/16" end mill, then file the corners square.
How would you do it if you didn't have a 7/8" square broach?