there has been a few times that i wanted to do internal splines but had no way (or hadn't thought of a way) to do them myself and i didn't want to have them edm'd. i just stumbled across this video and a light bulb light up in my head. i am sure it is not the most efficient way to do it but i like to make do with the tools i have available.
i would need to rigidly lock the spindle to use a holder like in the video or fabricate a holder off of the spindle housing. before i put anymore thought into this, is there any risk of damaging the machine? would this over load the steppers?
[nomedia="http://www.youtube.com/watch?v=8gC4nbVB1-8"]YouTube- Rick CNC Cutting a Internal Spline[/nomedia]