Grinding Ball End to Hex Key

[white91formula]

Has anyone successfully reground the ball end onto a hex key ?

I have a almost new set of T handle hex keys and i snapped the ball end off of the 3/16 one. Most of what I do i need the ball feature.

Anyone have any suggestions for grinding a new ball onto it ?

 

[rlitman]

Get a replacement. Does it have a warranty?

 

[William Payne]

I think I could probably pull it off in an extremely crude way with a linisher. But honestly if I had to do that I’d be asking myself why I’m not just buying a new one.

 

[Kevin54]

Has anyone successfully reground the ball end onto a hex key ?

I have a almost new set of T handle hex keys and i snapped the ball end off of the 3/16 one. Most of what I do i need the ball feature.

Anyone have any suggestions for grinding a new ball onto it ?

A new ball driver is way cheaper than what it would cost to put a proper ball back on the key.

And if the key that broke is the commonly used key...buy a couple extras.

 

[rlitman]

A new ball driver is way cheaper than what it would cost to put a proper ball back on the key.

And if the key that broke is the commonly used key...buy a couple extras.

Agreed. Re-grinding the ball profile may be more difficult than end-mill sharpening.

I don't throw out broken ball end keys. I just grind them flat.

Remember this: hex fasteners strip out too easily as it is. Do you really want a hokey hand ground ball end too?

 

[Slednut]

Just saw this thread, walked out in the shop clamped my Dremel in a vise and went at it. It worked, the T-handles I have don't have a ball but this set does and one was broke off. I always use the short end to break the screw loose and then use the ball end.

I'm sure that if I did it again I could do a better job. After a few a guy could get really good at it.

 

[American Locomotive]

In the factory, they use a special process called polygon turning, where the key is chucked in a lathe, and then a special cutting head that's synchronized to the main lathe spindle cuts the profile into the hex key.

You can definitely get something close by hand grinding it, but the geometry definitely won't be right, and it'll probably damage fasteners.

 

[bullnerd]

Yes.

 

[rbgearz]

Used to do it all the time. Take your time and it will work fine.

 

[joe_padavano]

I've done it in a pinch when I absolutely had to have a ball end allen in a size I didn't have. Of course you can do it. It won't be pretty, but it will work.

 

[white91formula]

Thanks g u ys. Got some free time tomorrow ill see what i b can b do.

Not worth the postage to send in for warranty. I like to try and fix things before just buying a new one.

 

[EdT]

Mc Master sells 5 1/2" long straight hex keys with the ball end. A 3/16 one is $1.38

 

[bonneyman]

In the factory, they use a special process called polygon turning, where the key is chucked in a lathe, and then a special cutting head that's synchronized to the main lathe spindle cuts the profile into the hex key.

You can definitely get something close by hand grinding it, but the geometry definitely won't be right, and it'll probably damage fasteners.

I always wondered how they kept the "waist" of the ball end at the perfect diameter but then both ends curved away - and the ball end maintained enough strength at the end of the process.

 

[Bottlecapdigger]

Yes I have, use too do it before they got popular. When I needed one I ground then on a belt grinder. 3/16 probably the smallest size I ever done. BCD.

 

[king nero]

I always wondered how they kept the "waist" of the ball end at the perfect diameter but then both ends curved away - and the ball end maintained enough strength at the end of the process.

When they break, it's at the weakest point - the "waist" just above the ball end. It only serves for losening/tightening an already loose bolt,
If you need one, they save lives, but you better also get a swivel end socket as these are more suitable for high torque/breaking loose a bolt...

 

[Doug Arthurs]

The way those things break off inside a bolt and then are a pain to get out I try and avoid them.