Broaching a Double D Hole

[fool injector]

To put the foot pegs in the right place, I had to make new mounts, with a Double D hole to locate the peg and fix it at the correct angle. A broach seemed the best way to shape the hole, so I made one. Picked a bolt that looked big enough, hammered it into the wedge shape in the picture, prepared the hole per the sketch, and shoved the broach through the workpiece with the 20 ton press. A little bit of hand finishing with files, and the job was done.