In bygone days, apprentice machinists and mechanics were colector de bonus royal story taught bench work skills which included laying out work, filing, chipping and scraping.
Portable Keyway Milling Machine Jinshaa Machines Portable Keyway Milling Machine The model JSM 304 Keyway Cutter is designed to mill?(6.35mm) to 1?
You should be able to put in a good keyway.Portable Keyway cutters were a common item in some old supply catalogs I have.Every old time machinist or millwright or mechanic had a portable keyseat cutter set in his toolbox- a few cape chisels, a ball pein hammer and some files.Scube International Delhi, parth Enginners Mahape Mumbai.Habile Engg Belgaum 2016-17, turbofix Engineers Consultants Mohali Punjab.
The tool incorporates a graduated depth of cut system.Axial feed is provided for by a manual ratched system.
They were sold as hand driven devices which clamped right to the shaft.
They are also expensive.
Take a die grinder with a small burring tool and hog out the webs between the drilled holes and along the sides to get the keyway approximately to shape.
Some grinding down of files to fit within the keyway will be needed.
However, if you must have a keyway in that shaft and don;t want to take the mill apart to make it happen, it can be done the old time way with a cape chisel and files.
Ramco Cements Ltd, root Nine International Dubai.