On this instructable, I will share the steps I took to replicate a key. Ever since I was little I've been fascinated by fire and crafts. When I found out I had access to a blow torch, I began to think of the possibilities. I came across the idea of replicating a key came to me after I saw a professional do it. It seemed like such a useful task and fun one to add on. So without further ado, here is the tutorial.
The materials you will need to replicate a key are:
1) any metal (preferably one with low melting point temperatures that aren't toxic such as tin.) 2) kinetic sand 3) an original key 4) something to achieve high temperatures with (I used a blow torch but I understand not everyone has access to one.) 5) a stainless steel pot
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Step 1: Step 1: Making Your Mold.
By placing your kinetic sand into a pot and pressing the original key into it, you will have created mold that is relatively heat resistant.
Step 2: Step 2: Melting Your Metal
Next, I used my blow torch to bring some heat to the tin roll. The liquid tin fell into the pot that was placed below it. I had a stove on just to keep the metal warm, but this is optional. Consider that tin melts at about 232°C and its preferable not to breathe in the fumes.
Step 3: Step 3: Pouring the Liquid Metal
Once you have enough metal to fill your mold, carefully pour it on top the sand so that the liquid takes in the form of the key. Leave the sand with the molten metal somewhere it can cool off and make sure you don't spill it over or touch yourself.
Step 4: Step 4: Finishing
After 10 minutes, by poking the metal with a stick, make sure the metal isn't still liquid and only after this, touch it slightly to see how hot it is. If it's cold enough to get out, then your basically done. You can use a filer to give it finishing touches or trim it as necessary but this is optional.
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