1) Zinc (You can buy it in a store as a slab, or pour your own)
2) Emery Black Polishing compound
3) Never Dull Polishing Wadding
1) Hacksaw or Jewelers saw
2) Metal File
3) Sandpaper (80,100,120,150,200,300,400, ect)
5) Dermal Tool with metal rasp wheel, and polishing wheel attachment
6) Drill Press
7) Time: Probably 3-4 hours
Step 1: Get Your Slab of Metal
Warning: If you do pour your slab of zinc, do not inhale the gasses, this should be common sense. Zinc gives off ZnO (Zinc Oxide) when melted and inhaling it can cause you to feel very sick. I shouldn't harm you too badly, but you still shouldn't inhale it.
Step 2: Make Your Template
Next you want to print out your template (2 just incase one gets messed up), then place double face tape on the back. Use an Xacto knife to cut out the "block in area". Then stick your template on your slab of zinc.
The H,M,L were areas in which I was going to make High, Middle, Low. Again overtime my end result was more simple. The Heart became High. The shaft of the key became Middle. The actual pins became Low.
Step 3: Blocking Out the Key
When vicing your piece make sure you place rags around it. This will stop the vice from making imprints on the metal. Zinc is relatively soft compared to metals like steel, so be careful.
Step 4: Adding Details
Step 5: Cutting the Key Teeth and Sizing
Because my metal was too thick I had to thin it down. To do this I just ran it back and forth on my file to reduce the size. Also doing this levels out the metal so that you get rid of any pits you may have created when smelting/pouring your zinc.
Step 6: Defining the Parts of the Key
To define the parts of the key we need to add a small change in elevation. To do this I used both, my Dermal as well as my file. Mark the areas with a permanent marker like I did and clamp the key down to a table or in a vice. Take your Dremel or file and slowly subtract material from one side of the line. This will define the heart, I also did this where the teeth of the key are. As you can see the areas are labeled H,M,L. You don't need to remove very much material only about 1/32 to 1/16 of an inch will work, just enough for your eye to see the different segments. Do this to both sides and your key will have a little more dimension.
Step 7: Holes for the Chain
Use a small drill bit to place two holes in the top of the heart. Mine did not come out 100% aligned, but thats what you get when working with very small objects on a large drill press. Either way, the chain hides the sloppiness of the holes pretty well. Make sure to have your chain before you punch your holes, you don't want to oversize or undersize your holes.
Step 8: Sanding and Polishing
Start sanding with 80 grit and work up to whatever grit you want to end with. Tip: The higher the number the better the piece will shine. Once you are content with sanding, you then want to use some Emery Black polish compound. Once done with that, wipe the pieces down with the Never Dull wadding for a nice shine.
I don't have any shots of me polishing the key, but it's pretty simple. Put the polish on your Dremel tool and go to town. Also the images below don't have holes in the heart area because I sanded twice, once before putting the holes in. I thought I was going to use the key for something else but then decided to make it into a necklace.
Step 9: Finished
Just run a chain through the necklace pendant piece and you're done. I had an extra chain at home, but if you don't have one they can be easily picked up from a local department store.
Your necklace pendant is complete, while it may not be perfect, and its easier to buy a necklace; doing it this way shows that you put real effort into your gifts. No relationship is perfect so why should jewelry that expresses your relationship be perfect.
I hope you guys liked this instructable, if you did please vote for it in the Jewelry Contest. If you have any questions leave them in the comments and I will try to get back to you as soon as I can.