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This Instructable is how to make a DIY State Shaped Magnetic Key Holder. You can also see the full blog post at: http://fixthisbuildthat.com/diy-magnetic-key-holder-state-shaped-plans/
Tools Used (affiliate):
- Miter saw or Tablesaw
- Drill press or Cordless Drill
- Bandsaw or Jigsaw
- Spindle Sander
- 1-1/4" Forstner Bit
Step 1: Prepare the Wood and Shape It
I used a nice piece of 1/2" hardwood walnut for my keyholder, but you can make yours with any size and thickness wood you want.
I printed out a Tennessee state shape from http://www.coloringcastle.com/state_coloring_pages.html (I resized it in PowerPoint). Then I used some spray adhesive and stuck it to the wood.
Using my bandsaw I cut out around the template lines. You can also do this with a jigsaw or scroll saw. Remove the template when done and you have your rough shape.
Step 2: Sand the State Shape
I used a belt/spindle sander to do the shaping of the flat sides and the gentle curves on the east side of the state.
For the detailed curves on the west side of the state I used a file, sanding sticks and regular sandpaper. Get the sides as smooth as you can without losing the detail then sand the whole piece to 220 grit.
Step 3: Mount the Magnets
The magnets I used are 1.26" rare earth magnets. I used a 1-1/4" fortsner bit to drill the holes along the bottom of the state. The key here is to drill down as far as you can without poking through the front. Set the depth on your drill press or mark your bit if you are using a drill to make sure the spur of the bit stops just before blowing through.
To mount the magnets I used a punch and mallet and knocked them in. I did not use any adhesive because the press fit was so tight.
Step 4: Apply Finish and Mounting Hardware
I used a boiled linseed oil finish on the key holder. This will allow easy refinishing when needed. I applied 2 coats and let it dry over night.
I used keyhole hanger mounting hardware on the back and mounted them between the magnets. Make sure not to drill through the front face of the key holder when attaching.
That's it, your all done! Just toss your keys up and watch the magnets snatch them.
YouTube video: https://www.youtube.com/watch?v=8Mf6eG2GvlU