May be a bit crude for you but an 1/8 in mill and a file may substitute for a broach especially in a non critical fit as this appears. Ted: Neat solution for adding keyways.

I am also thinking Ted as you have an original counter weight, some material, bluing, a band saw, and a belt sander, along with a couple of drills and a Mill might suffice to rough out a suitable copy. Lots of time involved, and you would really need to want one.

The trough would be a major task if the original was to be duplicated but a simplified version could be roughed out. 

I agree. No broach is needed. A die grinder, Dremel, jig saw, band saw, hack saw, etc can be used to start the notch. Finish it with a file.


Lawrenceville, GA

thanks for the tips

i'm not above finding alternative methods    i'm hoping to borrow the broach from a model engineer friend. if not i've considered drilling a 5/32 hole on the circumference of the 1" hole prior to drilling & reaming said hole this would give me a notch that would require minimal filing for the keyway

i've got a 25mm drill bit that should leave enough meat for a 1" spiral flute(needed to stop shudder on the pre drilled notch) reamer to work on

another problem with the broach is that the counter balance will need to be backed with a piece of scrap to prevent it dropping between the teeth   i wondered why they are advertised with a min cut

thanks again everyone

stuey

  

all i need to do now is try to do a static balance with an old eccentric!!

 

next the oil trough but thats on hold   the wifes pulled a muscle in her leg and is in great pain so i'm the "go fer"

thanks Ted and everybody else      this is a great site for beginners like me

stuey