Alexei Volkov
There are many reasons why you may need a spare key. Whether you've lost your original or are just being cautious, it's useful to know how to make a copy. There are several ways to do this, including engaging a professional locksmith or hardware store, or making one yourself at home. One method of copying a key at home involves using plastic. This can be done by making an impression of the key on a plastic card, tin can, or similar material, and then cutting out the shape with scissors. This DIY method can be completed in a few minutes, but it's important to be careful and accurate when creating the duplicate.
| Characteristics | Values |
|---|---|
| Method | Copying a key by casting |
| Materials | Plastic card, tin can, plaster, molten zinc, carpenter's wood filler paste, flour, dried-out compound, liquid plastic, epoxy |
| Tools | Lighter, clear tape, scissors, utility knife, small coping saw, small jeweler's files, mini files, Dremel, abrasive cutting wheel, flathead screwdriver, lockpicking tension wrench |
| Time | One day |
| Cost | Low |
| Difficulty | Medium |
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What You'll Learn
Using a plastic card
Next, cut out the shape of the key from the card using a pair of scissors. Be very careful and precise while cutting, especially around the teeth of the key. If the teeth are not cut accurately, they will not be able to turn the lock. It is also important to ensure that the teeth are not distorted. Once the key is cut out, try it in the lock.
If the key does not fit smoothly, you may need to bend the key slightly, especially if you are using a stiffer plastic card. You can also use a small flat-head screwdriver or a lock-picking tension wrench to turn the key. It is important to note that this method may not work for all types of keys, especially those with transponder chips. For such cases, you may need to visit a locksmith or a hardware store to get a copy made.
Additionally, when creating the key outline on the tape, make sure to avoid any raised letters or numbers on the card. This will ensure that the copied key is not too thick to fit into the lock. Using a light-colored card can also help you easily see the imprint of the key and cut it out more accurately. Overall, this method can be a quick and easy way to create a spare key in case of emergencies.
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Cutting out the shape
To cut out the shape of a key, you will need to have already prepared a plastic card with the key shape imprinted on it. You can do this by using clear tape to make an outline of the key with the exact dimensions of the original. The outline of the key will be on the clear tape, which can be transferred to a plastic card. You can use an expired credit card, a plastic gift card, or a plastic bottle lid.
Once you have the outline of the key on the plastic card, carefully cut out the shape with scissors. You will need to be precise and careful when cutting, especially around the teeth of the key. Make sure you cut directly on the outline, as teeth that are not the correct size will not be able to turn the lock.
If you are using a plastic card, be mindful of any raised letters or numbers on the card. The tape should be placed away from these to avoid the card becoming too thick to fit in the lock. You should also use a light-coloured card so that you can easily see the imprint of the key.
If you are using a plastic bottle lid, you will need to burn the inside of the lid with a lighter first. Hold the teeth of the key over an open flame until they are charred, then stick the tape to the blackened side of the lid. This will create a more durable key copy than a plastic card.
Once you have cut out the shape of the key, you can use a small flathead screwdriver or a lock-picking tension wrench to turn the key if it is too flimsy. On stiffer plastic, you may need to bend the key slightly to make it fit into the keyway better.
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Making an impression
Another method involves using a plastic bottle cap. First, use pliers to flatten out the bottle cap, removing any creases. Then, place the tape with the key imprint onto the bottle cap, and cut out the shape of the key. Again, accuracy is crucial, especially around the teeth.
For a more complex process, you can create a mould of the key using plaster or a similar substance, such as dried-out carpenter's wood filler paste mixed with a small amount of water and flour. This method is more time-consuming due to the drying time required for the mould. Once the mould is dry, use a utility knife or small saw to create a channel at the top of the mould for the molten metal to flow into. Additionally, cut small air vents to allow the air inside the mould to escape when the metal is poured. Tape the mould together with electrical tape or secure it with rubber bands.
These methods of creating impressions of keys can be useful for making spare copies of your keys, but it is important to remember that copying someone else's key without permission is illegal.
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Casting the key
To copy a key by casting, you will need an impressionable substance capable of withstanding molten zinc at around 800°F. Plaster works well for this purpose, but it contains a lot of water and takes a long time to dry. A faster alternative is to mix carpenter's wood filler paste with a small amount of water and flour until it forms a thick paste.
Once you have your moulding compound, press your key into it to create an impression. When the compound is dry, use a utility knife or small coping saw to cut a sprue channel at the top of the mould for the metal to flow into. Make the top of the sprue wider, like a funnel, and cut some tiny air vents in the mould to allow the air inside to escape. Tape the mould together with electrical tape or rubber bands.
Now, pour molten zinc into the sprue. Allow the metal to cool, then cut off the sprue and air vents. Use small jeweler's files to smooth out any rough spots and remove extra bits stuck to the key notches. Lay the original key over your copy as a template and file until the dimensions match. Test the key in the lock. Once it fits smoothly and is able to turn, you're done!
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Using molten metal
To copy a key using molten metal, you will need to create a mould of the key and pour molten metal into it. Here is a step-by-step guide:
Preparing the Mould:
- To create the mould, you will need an impressionable substance capable of withstanding the high temperatures of molten metal. Plaster of Paris is a popular choice, but it contains water and takes a long time to dry. A faster alternative is to mix carpenter's wood filler paste with a small amount of water and flour until it reaches a thick consistency.
- Place a thick layer of your chosen mould material in a small container and gently press the key onto it. Ensure the key teeth are fully embedded in the mould material.
- Leave the mould to dry completely. This may take several hours.
- Once dry, use a utility knife or small saw to cut away at the top of the mould, creating a channel for the molten metal to flow into the key impression. Make the top of this channel wider, like a funnel, to facilitate the pouring process.
- Also, create some tiny air vents in the mould to allow air to escape when the metal is poured. Ensure these vents are not too big, or the metal will leak out.
- Choose an appropriate metal for casting. Zinc is a common choice, but it has a lower melting point than other alloys and may not be as strong. Rose's Metal is a popular alternative, as it has a higher melting point, is mechanically stronger, and does not contain cadmium.
- Heat your chosen alloy above its melting point. For Rose's Metal, this is approximately 98°C.
- Quickly pour the molten metal into the mould, being careful not to spill it outside the mould.
- Allow the metal to cool for a couple of minutes, then carefully open the mould.
- Remove the key from the mould. You may need to use a small file to remove excess material and refine the shape of the key.
- Test the key in the lock. It may require some adjustments and refining to fit smoothly and turn the lock.
Remember, always exercise caution when working with molten metal, and ensure you have the necessary safety equipment and ventilation.
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Frequently asked questions
The first step is to use a lighter and clear tape to make an outline of the key with the exact dimensions of the original.
Transfer the tape onto an expired credit card or plastic gift card. A standard thickness card will work best.
Cut out the shape of the key with scissors. Carefully manoeuvre around the outline of the key, being mindful of the teeth, and cut directly on the outline.
You can use a small flathead screwdriver or a lock-picking tension wrench to turn the key. On stiffer plastic, you may need to bend the key to make it fit into the keyway better.
