I'm needing to make a cardan block to replace this scrap one (photos below – I hope). I think the machining is fairly straight forward but I would like to ask the experts two questions, if I may.

The slots/grooves need to be cut pretty accurately and I'm wondering what is the best way? I can see one approach might be to broach them, but I don't have any broaches, and even if I did, I don't think my one ton bench press would push a sufficiently sized broach through.

Can I do it with a slot drill(s) or end mill(s) working vertically and outwards from the through hole?

Secondly when it comes to making the bronze cardan blocks – they sit on a pin in the end of the cardan shaft and must slide freely in the slots – what is the best way? I'm thinking the simplest (though not the most economical) might be to start with a disc the same diameter as the depths of the two grooves plus the diameter of the through hole and about the required length as the blocks. Then, cut away the top and bottom of the disc to leave a flat piece of bronze the height of the blocks and remove the centre portion to achieve the bocks thickness. This seems likely to have a better chance of success than trying to accurately trim and shape a piece of square bar to slide along the curved wall of the groove?

Any suggestions/advice/encouragement, as always, most gratefully received with many thanks in advance.

Martyn

PS One word answer to 'buy the blocks'. Brexit. I won't expand for fear of being 'modded off'.