With the development of so many consumer, DIY and kit CNC mills, lathes, Laser-cutters, 3D-printers and other assorted NC machines that line our wishlists it can be easy to forget that a lot can be accomplished with manual tooling.
This is a part that was machined up mostly using hand tools after a manual lathe was used to turn the basic profile.
The part is a sector gear for a Holden HQ ignition. It transmits the twisting motion from the ignition key to a rack gear which locks the steering column and actuates the ignition & starter switches. This was made when the original part failed in service (mind you the vehicle was over 33 years old). A replacement was available but the lead time of more than a week would have left me without transport for too long.
The profile was copied from the original part and fabricated using a hacksaw and small hand files. The finish was achieved by glass bead blasting and still looks as good as it originally did several years later.