Modify your keys to fit in a leatherman. This is a real clever way to pack some spare keys around. You can fit up to six keys in one mini multi-tool.
Step 1: Materials
NOTE: Let me first state that I stumbled on this Idea browsing through the edcforums. There was a post a while back where user, shadeone had posted some pictures and a short tutorial on building one of these sweet little babies. Check out the original forums thread started by shadeone here. I take no credit for originating this idea, I've just documented my own experience building one. This is a modification to his original half micra design which allows me to keep the pliers and a few tools.
Also Stop by http://mathewmullen.com for more cool projects.
Leatherman Micra - ( I used a cheapo Husky clone that I got at home depot for $2)
Keys - (be sure to make copies of them first)
Something to cut the keys with - (I used a Dremel with a cutoff wheel.
Step 2: Disassemble the Multi Tool
Start by unscrewing and Disassembling the tool. Make sure you save all of the little parts and washers. Note that I was able to fit 3 keys per side so only undo one side if you are doing 3 keys or less.
Step 3: Select a Matchup Piece
Set one piece aside to use to match your key against when you are cutting it.
Step 4: Cut Your Keys
Cut down your keys to roughly match the end of the piece you picked in the previous step. You will be drilling a hole in them so be sure and leave as much meat as possible. You can fine tune it later.
Step 5: Mark and Drill the Holes
Place each key one at a time inside the tool in the direction you will be placing it and mark the hole with a fine point marker through the hole in the tool. I placed mine teeth down so it is easier to pull them out by hooking a fingernail in the grooves across the top.
Once you have marked all keys, mark your starting points with a punch or nail and drill your holes. The size of the hole may vary depending on what kind of multi tool you choose. Start small as you can always bore it out more if necessary.
Step 6: Put It Back Together
Re-assemble the tool substituting the keys for the tools. Be careful of three things. 1) Be sure you put a washer in between any metal-on-metal contact. 2) Make sure you place the keyring attachment piece somewhere where it will not interfere with a key. 3) Most importantly, remember to leave a gap in the middle of each side for the pliers/cutters to fit into when you collapse the tool. ( I placed two keys all the way to one side, then a bunch of washers and then a key against the other side.
One little tip: If there is a skinny leather punch or mini screw driver piece, you can stick this through the hole when re-assembling the tool to help keep the washers and the pin in place. This also worked well to wiggle around to get everyting to fit together properly.
I was thinking for my next attempt to use a slightly wider, folding style alan wrench set and try to get a bunch on each side.