Introduction: DIY Swiss Army Key Holder by BCDesign01

About: I like to make fun projects and document it all for my channel BCDesign on YouTube!

Do you ever have problems finding your most used keys in the bunch you carry? I made this Swiss army key so I know where my most used keys are at all times! I just put it in my work trousers cargo pocket and know its there when I need it!

Watch the video I made for my YouTube channel BCDesign it will help you understand the following Instructable steps!

What you will need:

  • Handsaw
  • Belt Sander
  • Drill
  • 6mm Metal & Wood bit
  • Hacksaw
  • Clamps
  • Superglue
  • Dremel or half round file
  • Jigsaw or scroll saw
  • 2 6mm bolts & nuts
  • 6mm washer
  • 2 keys
  • Danish Oil (or other finish of your choice!)
  • Sand paper 240 grit

Step 1: Cut the Aluminium & Drill the Bolt Holes

  • Lay out your keys on the aluminium and mark their position, making sure to leave room between the shanks of the keys for the washer that will be used as a key stop later.
  • Mark the position of the hole in each key, the 6mm bolts will pass through these holes.
  • Use a vice or bench hook & clamp to hold the aluminium pieces while you use your hacksaw to cut them.
  • Spray some wd40 on the points you marked for the bolt holes.
  • Clamp the 2 pieces of Aluminium together and drill the holes at the same time
  • Use a drill and the 6mm metal bit to drill the holes, the wd40 will stop the tip of the drill bit from overheating.

Step 2: Mark & Cut 2 Semi Circular Finger Grooves

  • Use something round a similar size to your thumb tip to mark where you will cut the finger grooves on one of the aluminium pieces.
  • The finger groves will allow you to grip the keys and open them easily later.
  • Use a Dremel and metal cutting bit or file to cut out the finger groves.

Step 3: Grind the 6mm Washer and Glue It to the Aluminium

  • Grind two flat sides on the 6mm washer.
  • Test fit the washer between the 2 keys.
  • Make sure both of the keys can close against the washer before it is glued in place.
  • Mark the position of the washer, apply some super glue and clamp it in place.

Step 4: Cut the Walnut & Drill the Holes

  • Mark the outline of the aluminium pieces on the walnut.
  • Use a jig saw or scroll saw to cut the walnut.
  • Lay your aluminium pieces on the walnut and use them as templates to drill the bolt holes in the walnut.

Step 5: Glue the Walnut to the Aluminium

  • Use a lollipop stick to spread the superglue on the walnut.
  • Insert the bolts through the holes in the walnut & aluminium to make sure the pieces are aligned.
  • Clamp the walnut and aluminium pieces together until the superglue is dry.
  • Make sure to remove the bolts so they do not get glued into place.
  • Use the dremel to grind the walnut around the finger groove to shape.

Step 6: Use the Belt Sander to Shape the Holder

  • Bolt the Swiss army key together & use it to round over all the sharp square edges.
  • If you do not have a belt sander you can do this with, you can use files & sandpaper on a soft sanding block.
  • Take the Swiss army key apart & give it a final hand sanding.

Step 7: Glue on the Nuts & Sand the Bolts Flush

  • Apply a small amount of superglue on the threads of the bolts.
  • Use a spanner or small ratchet to tighten the nuts onto the bolts.
  • The bolts I used were a bit too long so I used the belt sander to sand them flush with nuts.

Step 8: Apply the Danish Oil

  • Use a cloth or kitchen towel to apply the danish oil
  • Apply 3 coats of oil on the Swiss army tool

  • Sand with 240 grit sand paper between each coat of danish oil.

Step 9: Finished!!

I really enjoyed this project it was quick, fun & is very useful!! The next time I make one I will use flush bolts instead of regular bolts even though I like the chunky design of this Swiss army key!

Check out the video if you didn't at the start of this Instructable & please vote for me with the vote tab at the top of the page if you liked this project!

MacGyver Challenge

Participated in the
MacGyver Challenge