Quote:
Originally Posted by G.T.
Hi Rich, I dunno?? I just know it takes a lot to push something bigger thru something smaller...  .... most of my experiences ended with stuck like welded results! I though one might mount a threaded fixture in a large, mostly linier thrust bearing, and let it, the barrel, turn as the button goes thru!  ..... I have been eyeing the button for sale on ebay.... Project number 9999! .... best to all,til...lat'r....GT.... 
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Gerry, my only experience in this area has been in cutting keyway slots in gears and pulleys. We used the appropriate width broach and an assortment of shims. The 'press' used a gear driven ram, with a long handle, for pushing the broach through. Use lots of oil, and if hard resistance is felt, a pipe on the handle. A half-inch keyway would require a quarter-inch deep cut in the gear/pulley. The shims were any convenient thickness; in this case, probably 1/32" or 1/16". Press the broach through and stack another shim, oil, and press through again. Broaches were ~18" long IIRC.
A rifling groove of only .004"-.005" would be easy. Making a 'rotating nut' with a twist of 1 in 10" might require some thought...