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Tips/Techniques Making the Square Drive hole in a custom socket.

Tips/Techniques
Susquatch

Susquatch

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Apparently, the dual counter - rotating propellers on a Volvo Outboard Drive system requires a special socket. The tool costs a King's ransom.

So one of my boys borrowed one and asked me if I can make one for him. For reference, the ID is 2.05", and its about 7 inches long. I don't know if the OD (2.38") is critical but suspect that it is. It might have to fit inside a prop.

20250322_101422.jpg20250322_101450.jpg20250322_101501.jpg20250322_101531.jpg

The socket part is easy. A 1/4" endmill will cut the slots. And if I can't find the perfect size thick wall pipe, turning the OD and boring the ID should be a piece of cake. In fact, if steel stock wasn't so expensive I'd just turn and bore the whole thing out of solid steel bar. But thick wall pipe is prolly cheaper.

My question to the gang is how to make the 1/2 (or maybe 3/4) square drive hole. Normally, I'd drill for the ID of the drive, then use a small endmill to rough out the square, and then file to dimension.

But I have a shaper coming some day soon and this seems like a great first project for it. What do the shaper guys on here think? How would you do this using a shaper?
 
historicalarms said:
I think your shaper idea is sound...but the "farmer fix" mind I have says "just weld an old socket inside your pipe....done...
Click to expand...

Ya, the farmer in me likes that too. But there is no way in hell that I'm giving anything to my son that I welded...... My welding works, but looks like someone did it using a 12V battery and steel breakaway cables. I reserve welding for things nobody will ever see or at least not ever know that I did it.

Also, big sockets are expensive too.......
 
historicalarms said:
I think your shaper idea is sound...but the "farmer fix" mind I have says "just weld an old socket inside your pipe....done...
Click to expand...
Honestly this looks a bit like how the one in the picture is made. I'd grab a spare impact socket (not plated) and use that as the drive end, and the pipe end is simple turn and slot.
Now if you want to use the shaper, then go ahead no reason not to, just more work but a good learning opportunity.
 
In shaper:
Mount tube et al in the vise using a v-block after drilling an appropriate hole for the square. The using a boring bar tool, shape away the corners. If you mark up the end with parallel/perpendicular lines first then you can use those to index.
 
Mike R said:
Honestly this looks a bit like how the one in the picture is made. I'd grab a spare impact socket (not plated) and use that as the drive end, and the pipe end is simple turn and slot.
Now if you want to use the shaper, then go ahead no reason not to, just more work but a good learning opportunity.
Click to expand...

See post above yours.

And yes, I need an early excuse to use the shaper.

My thoughts on this project have evolved quickly. It seems my son's 3 sons (three of my 8 grandsons) want to he involved to help make this for their dad. So there won't be any welding. Guys who can't do should never teach...... (ya, I know, that doesn't stop a lot of teachers). But the idea of supervising their build of this has my mentor senses tingling. I just have to break this down into manageable parts according to their age (12,14,16) and abilities.

Now I'm excited! Gunna go the solid bar route! (more work but also more of a feeling of accomplishment for the boys!
 
gerritv said:
In shaper:
Mount tube et al in the vise using a v-block after drilling an appropriate hole for the square. The using a boring bar tool, shape away the corners. If you mark up the end with parallel/perpendicular lines first then you can use those to index.
Click to expand...

What does a shaper boring bar look like Gerrit? A little like the working end of the first tooth on a broach?

Loving all the learning!

And another chance to say thank you Gerrit!
 
Another piece of info. He has borrowed the tool for this spring. A tool of his own can wait till fall.
 
I've made a few specialty sockets. Most times I go to my box of misfit tools, grab an old junk socket, and weld it into the new one....

I've also got a HSS square toolbit that I've ground a round shank on, and use that as a quill broach. Might be tedious, and time consuming but you could nibble away at the square hole. I mostly used it to clean up inside square corners from cutter rads when they absolutely needed to be square.
 
Dan Dubeau said:
Most times I go to my box of misfit tools,
Click to expand...

I don't have such a place in my shop. It's a problem finding places beside existing tools for all the misfits. Yours is a great idea. A separate place for misfit tools! I like it!

Dan Dubeau said:
I've also got a HSS square toolbit that I've ground a round shank on, and use that as a quill broach.
Click to expand...

Got a photo Dan? I can't quite picture that in my head.
 
Almost heading out the door, can't find the bit, but here's a quick model of what I'm talking about. Just a square toolbit with a cutting edge ground on the end, and a round section ground into it to hold in a collet. Hold the brake, and plunge with the quill stepping over a few thou each time. Goes quick and easy. 8-10* cutting edge from both sides should do.

toolbit.png


I had a deja vu moment while looking for this, and I'm pretty sure we've talked about this before and I couldn't find it then, but was going to make a couple new ones. I DID find 3 different size bits layed out on my surface plate waiting for it lol.

While drawing it up, I got thinking that one could make a holder out of steel with a square recess, open sided on one side to cut with an endmill, but with a cross hole to set screw clamp a toolbit in it. No time to model that, will later. Wife at the door angrily waiting for me to leave.....That's a first....I got "the look" while typing that out loud....:D
 
Johnwa said:
Why not a T handle?
Click to expand...

A T handle was my first thought too. Just drill a cross hole and stick a bar through it.

But,.... He has borrowed this tool and used a torque wrench with it, so he is spoiled.

Besides, this would be my first legit use of my new to me shaper..... LOL!

Also, the more things to do with different machines, the better the lessons for the boys!

Johnwa said:
mill a hex on the end the bar and use a regular socket.
Click to expand...

That only works with bar, not pipe. Also, I have 2" sockets for the farm, but he doesn't and they are not cheap either.
 
Millwrights make custom sockets all the time by welding a sockets on the end of a pipes. I've a few really deep sockets by cutting a socket in half lengthwise and welding in a pipe. They really handy on pullers. I made a special socket that way for my little blue band Mercs.
 
MrWhoopee said:
I would just buy a 1/2" drive socket, mate it to the front end and TIG it.
But then I'm not looking for something to justify a shaper purchase.
Click to expand...

Also, apparently you have TIG and know how to use it. Which excludes me from your thinking.

But ya, definitely looking for an excuse to use a shaper.

SWMBO - WTF is that new machine you got?

HWMO - It's a Shaper honey! I needed it to make that custom propeller wrench for our son. You know, the wrench he had to borrow because he couldn't afford one of his own! It's for that new 200ft boat he got for his wife and our grandkids.

SWMBO - OHHHH! That new machine of yours did that! Well it's about time you bought something useful! I'm getting very tired of all the stuff you buy for this stupid farm you know!

HWMO - I know, but don't forget that the farm let's me write off the machine I got to look after our son's family.

SWMBO - OK, I didn't think of all that. It turns me on when you do stuff for the kids you know.

HWMO - Ya, I can be pretty thoughtful when I try.

SWMBO - You wanna?

HWMO - Again? :rolleyes:
 
Downwindtracker2 said:
Millwrights make custom sockets all the time by welding a sockets on the end of a pipes. I've a few really deep sockets by cutting a socket in half lengthwise and welding in a pipe. They really handy on pullers. I made a special socket that way for my little blue band Mercs.
Click to expand...

Weld weld weld..... It seems like that's the answer for EVERYTHING!

I have welders! I just don't know how to make a nice weld!
 
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