I faced the end and brought the end lip to the correct thickness. Bigger...

This is a set of clamps I made for holding the 4-jaw chuck in place on the rotary table. The chuck is screwed on in the center, and the clamps are just to ensure that the chuck doesn't unscrew. Bigger...

The 4 jaw chuck has been transferred to the rotary table and is secured using the clamps in the previous photo. Bigger...

This shows the hex being machined. 1/6 of the hex was machined at a time and then the rotary table was rotated. Bigger...

This shows the finished hex hole. The brass nut has spines down the center which engage with spline on the axle. The brass nut was part of the vehicle base that I'm using for a robot I'm building. Bigger...

I wrote a perl program, which I called Hex.pl to generate the G-Code. There is a variable near the top of the file called $sim. Setting this variable to 1 causes Hex-Sim.nc to be produced, which is what I used to generate the simulation pictured here. Setting $sim to 0 generates Hex.nc which is the file I used to machine the actual hex. Bigger...