The Home Machinist!

Got a chart for a 1040 steel, closest that I could find. 5 mb pdf file. email address?

For most alloys, there are charts of hardness vs tempering temp. There is also a rough chart of hardness vs strength. You should be able to find tables or charts on line. I will try to find a sample cahrt,

From what little I have done, your tempering temperature seems to be on the high side. But it all depends on the strength/ductility combination you want.

Too bad they are not half that width.

I have also cut down a few shanks without incident. As an option , I have made a few custom tool holder blocks that take a larger shank.

Not too hard to do, just finished a few for a brake cable on a 4x4. I would post a picture, but would have to crawl under the vehicle to see it! Drill center hole, cut hole for the ball on the cable from the side with a ball end mill, slot for shank with a small end mill. This one used a small cross...

diagonal cutting pliers work great.

Die heads are a wonderful tool, they make great threads except when you put a chaser, actually has to be two, in the wrong slot.

Part salvaged by making a new stub thread, cutting off the bad end, and hot gluing on a good end. 7/8"-9 example shown.

Thanks, A one of those why did I not think of that concepts. Might even have a broken center drill to test with.

I like the Bi-metal ones. Several shops in ebay that sell many grades and sizes.

Unless a motor is special as to features or sentimental value, it is normally quite cheaper to replace them than to repair.

Most interesting. I would have thought the bit spline drive would have been run dry to avoid accumulating and holding grit. Learn something every day.