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:
- Belt Sander
- 6mm Metal & Wood bit
- 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!