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You'd be around the cost of the broach, wouldn't you? I bet tap companies would turn pale, shut their doors, and place the "gone fishing" signs in their windows if you showed up with a print and...

Well, you could have a broach company make a "for real" broach for that, but I hate to think of the cost. You'd also want a special seat for the part with a good (shielded) thrust bearing on it to...

Sounds good. Is this a one-shot, or a run of parts? If one shot, either try the home-made single tooth broach, or if there's money available, you could find someone with a helix-capable sinker EDM,...

John, if I'm interpreting this correctly then this is basically a twisted spline, with a full revolution of one spline "thread" being completed in 111mm.

OP, correct me if I misunderstand. And...