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  1. #4
    I would look at getting the splines wire eroded by someone local to you. It may be expensive but the end result will be perfect and you can even do it on hardened materials without the need to anneal.

    If you need some contacts let me know.

    Just had a thought, how about water jetting it?
    Last edited by komatias; 13-03-2015 at 12:25 PM.
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