You'll notice that the device shown in this Instructable is different from the one in the video . The device in the video is the original I built for Mom which is still going strong. The one shown in this Instructable is the one I built for myself. It promptly broke on the fifth or sixth use. This is because I used a wood the was too soft and incorrectly placed the key notch. I'll describe these errors and how to avoid them in later steps.
Step 1: Tools and Materials
I used the following tools. As always if you don't have them you can acheive the same effect a different way with what you have...or use it as an excuse to buy a new tool.
* Tape measure
* Bench vise
* Work piece protectors
* Straight cut router bit (I used a 1/4" bit. This will vary depending on the thickness of your key.)
* Drill with 1/4" bit
* Wood burner with tips (Optional)
Step 2: Measure Your Key
With the bit installed set up your router so the bit will only cut halfway through your dowel. This will give the key turner a lot of surface area to grab, and allow the dowel to keep its strength.
Step 3: Drill, Route and Saw
The first thing I did was drill a 1/4" hole in the end of the dowel. This will allow a piece of string or wire to be run through so you can hang the turner in a convenient location in your car.
Next use the router to cut a notch near where the dowel is sticking out of the vise. I had to make two passes to get all the material so the notch was even.
With the notch done I then cut the dowel off about a 1/4" below the notch. I should've cut it off at least a 1/2" below the notch so it would be stronger.
Step 4: Sand and Finish
For the turner documented here I choose to use my wood burner to make a pattern in the wood. It looks cool and the pattern helped enhance grip. Another option would be to use the rubber tool grip stuff I used in making my work piece protectors.
However you choose to decorate it, you will have a handy device that will allow you to turn your car key without screaming in agony.