Step 1: The Keys Housing and other Materials
- Washers (some that will fit around the shaft of the housing)
- rubber grommets (same inside diameter as the washers above)
Step 2: The Keys
Step 3: Modifying Them
- A Bench grinder
- A Dremel tool with cut-off disk
- Some small Files
- A drill bit (I used a 1/4" bit)
- a de-burring brush
- Drill a hole into the key where I wanted the shaft of the housing to pass through.
- Trim the sides of the key down with the Dremel using a cut-off disk.
- Round the edges with the grinding wheel.
- Then de-burr the key so it has no sharp edges when we have cut and ground it down.
Step 4: Making a Key Ring for it.
- Take the bend out by removing the screw and stretching it into a semi-flat strip.
- Then I placed it on one end of my sledge hammer and pounded it flat with a regular claw hammer.
- After it was flattened I rounded the corners smooth with the grinding wheel.
- Then drilled a 1/4" hole in one end and de-burred the whole thing.
Step 5: Putting it all Together
Shaft screw, housing piece, #2, #0,#0,#0, H KEY, #0, Washer, Key Ring, #0, H KEY, #0, H KEY, #0, rubber grommet 1/2, Housing piece, end screw.
Shaft screw, housing piece, #1, C KEY, #2, Washer, C KEY, #0, rubber grommet 1/2, Washer, Washer, rubber grommet 1/2, Housing piece, end screw.
The reason it is in the order it is, is because we need the keys to slid between each other when we fold everything together. This is the order I came up with to have everything mesh nicely.
And you are done. This works well for elderly people who need some extra strength when using keys, just make sure you do not turn it too hard or the key could break in the lock, they are not fun to remove when broken.