machining splines on a shaft

I have a Rotex vertical head that has the threads on the spindle nose about worn out. It has the double taper Y type collets. I am thinking of either machining a ER20 collet on it (will be very close for the threads if I use the mini nut with M24 X 1.0P threads) or making a new shaft with ER20. I could use a PCH-ER20-1000S-10L from Craftsman Industries Inc. Which has the ER20 nose and a 1" shaft 10" long which is just the length I need. My only problem would be the splines on the end. I looked in the Machinery handbook but they start off with a .75 shaft. I have a .625 shaft with 6 straight sided splines. The splines are .150 wide and have a root dia. of .530. I don't know how to figure out what cutter I would need for this. I could do it with 2 slitting saws and mill out the middle but I was hoping to find out what the real cutter would be for this with the radius for the minor dia. Any other info needed let me know. Thanks for the help.

Ironguy

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