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!