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Depending on how thick a piece of O1 you're using, I dopubt the teeth will cause a problem in HT. If you think about it, unless you're making a broach thinner than you usually leave the edge of a blade for HT, you shouldn't have a problem.
Depends on the profile of the broach.
Thickness matter less than the shape does.
I made one one time out of O1 for a different industry, and it curled up about half an inch over 6" of length.
If you are making something that looks like a standard keyway broach, cut material off of both sides, not just the teeth.
Please forgive my ignorance... I understand what a keyway is, our print and die cylinders at work have them to keep the gears from slipping on the shaft. Am I correct that a broach in a tang is a notch to accept glue or handle material, like a keyway would accept a key?
Thanks for the link, Mike. That's a neat little tool. Most all my forged blades are full length hidden tang and I always spend LOTS of time fitting handles. Gotta make some of those. I use Roto-Zip bits in the dremel as they are designed to cut sideways. They could be a little longer but they work.