hex drill bit
 

anyone have a hex drill bit? i want to drill the hex all the way through on my wheels.
thanks!

ummm wanna explain that one?

Like a drill that makes a hex shaped hole?

A drill bit spins... it makes round holes...

Hexes in metals tend to be cut with a broaching tool, after the center is first drilled or machined out.

There are sqaure cutting bits for mills, but I do not think they have them for hexes?

Like this?

http://pergatory.mit.edu/2.007/Resou...G_image015.jpg

http://pergatory.mit.edu/2.007/Resou...G_image013.jpg

those are hammer bits.

You will need a broach to hex an existing hole, as stated/shown by Etype R and Micropuller.

Edit: I moved this to Tools and Procedures.

I am assuming these are existing aluminum wheels, not wheels you are making from scratch. Also assuming you have four wheels to do and not twenty.

Drill small holes in the corners of the hexs. Use a jewelers saw to connect the holes. Finish with a small 3-corner file.

I have done similar things in the past (square and hex holes in >1/8" steel) with just a small 3-corner file. Drill out the center hole as large as possible without messing up the hex. Clean up the corners with 3-corner file.

Jewelers saw http://www.jewelrysupply.com/jewelry...es_frames.html

If you have a lot of wheels to do, get the hex broach.

nope, just 4. actually i was joking about the hex bit but serious about hex'ing all the way through. i'll post a teaser pic or 2 soon to show what my thinking is.

well lets see the pics.

Still waiting..........

ok, here is my brain fart
Attachment 36419
a V1 reversed on a clod or txt knuckle. with the hex hex'd all the way through and a plate attached to the wheel to keep it in position on the hex/nut tightened down against. i got a set i'm not really using, i might try it, hopefully it wont turn out a waste of a set of wheels.

I've been thinking about doing the same thing. I just haven't convinced myself I want to manually cut a hex out of metal (or plastic) yet.

well i got existing drill holes to guide drilling all the way through at each point, then i'd drill the majority out and file the round into hex. i would try it now but my dremel drill press is at my sisters house.

Don't forget,any modification to the wheel WILL void the warranty.

lol....how would hacking the hex void the warranty?!?

I was thinking more along the lines of making an adapter plate to go on the back like run2jeepn did. You wouldn't want to tackle something like that would you? :)

heres a pic of adapters i modified i did the hex by using a small end mill
the way Dumster said would work also

http://img.photobucket.com/albums/v6...e/IMG_1642.jpg

Making a cheap broach
 

If you want to make a broach, (for aluminum) there is a simple solution that works, and I use it in making a special part for a particular person, It is simple, inexpensive and works well..........first off you need to know the hex size, by measuring across the flats you can get the diameter of the hex, next go to your local farm and fleet, or any other store that sells tools, purchase a allen wrench, of the size hex you desire, next you need to do a lil bit of modification to your new allen key, cut the bent end off so it is just a straight hex, now, there are several ays to perform the next part..

#1 clamp the hex vertically CENTERED below a drill press or milling machine chuck, then using a rounded bottom (pear shaped or round shaped) carbide deburring bit and some light oil begin grinding into the end of the hex untill you end up with a inverted concave cup in the end, that extends outward untill the circumference of the hex key is sharp all the way around....

OR

#2 if you dont have a drill press or mill, using a dremel tool you can do the same thing, but must exercise great care and patients not to damage yourself, or the end of the key, using a round deburring bit, or similar you can end up with the same outcome, just takes ALOT longer and is tedious..

Then make sure you have a hole the same size as the hex states...7/32 hole to make a 7/32 hex...etc etc.....this is because the hole is across the flats, and the hex is only to cut the points and add the hex shape to the original hole, then take your hex broach, and using an arbor press with a hole drilled in the end to fit hte broach, OR the quill on your drill press or mill, chuck the broach in the chuck and press it through the hole ar as deep as you feel you need.

You may need to retract often and using a tool to remove the curled inward material to prevent loading, or runnning the drill bit back in briefly, but this method does work, and I use it myself, I have made quite a few parts with my broach, and the hex is near perfect, actually was a tad on tight side, but was easily worked in but running the broach in and out of hexed hole untill it was easy to insert and remove.............

NICE! I like reading things like that. Good tip. Off to buy a set of big allen wrenches

So if I'm understanding the method correctly, a broach is basically a punch in the right shape you need (in this case a hex)?