Abstract: A spark wheel blank is provided with spaced helical grooves and lands or the like, as in a conventional threading or knurling operation. The blank so prepared is forced coaxially through the bore of a broaching die having a plurality of circumferentially spaced cutting surfaces which cut spaced notches across the lands to form a plurality of axially and circumferentially spaced teeth on the blank. The spark wheel thus formed is then subjected to an additional broaching step to remove portions of the teeth formed in the first broaching step, providing sharpened teeth for improved sparking performance.