My First BRAMAH-ish Lock

[jbrint]

Best part about brazing is you don't have to be particularly good at it so long as you are good at sanding. Ideally a good clean braze but a hot mess can be cleaned up to look quite nice. It happens.

[kwoswalt99-]

I think for key making, silver soldering is the best option. It matches the steel pretty nicely. Brazing is better for repairing fractures, it it's not a clean joint it won't be very strong.
I would recommend getting a jewelers torch instead of an oxy acetylene rig, because it's kinda overkill if you're just going to make keys. I heard somewhere that they stopped producing acetylene, I don't know if it's true though.

[femurat]

Thanks for the ideas about soldering, brazing and silver soldering. I've talked to a local expert that concur about silver soldering being my best option. I'll look into that eventually.

Following a suggestion by FrenchKey, I've made a 3D model of the key blank with my PC and sent it to be printed in brass. It's a bit less than 50 euro to get the key printed and shipped to me. I should get it next month. Once I get the key blank I'll make the cuts and hopefully it will work smoothly. Now I can concentrate on the box design.

Cheers

[femurat]

Today I got a gift a friend made me with a laser cutting machine. It's a flat blank he made based on my 3D model. I just need to round the edges and I may have a nice stainless steel blank. I'll keep you updated about my progress.

Cheers

[femurat]

I flattened the key tip and carefully drilled a 2,5 mm hole in it. I was thinking to make a gig to help me keep the key parallel to the grinder, or even better, a cutter on the drill.
Then I took out my flat file and started filing the sides round. I cut a slot in a wooden block to help me hold the key. I was almost done when my girlfriend came home and I had to stop and hide the key. I want this to be a surprise. I'll go on filing soon

Cheers

[femurat]

So I used a drill bit in the vice to be sure the key was round and centered on its hole. Made a few unsatisfying tries with the file, that seemed not to work very well because it was not easy to file and rotate at the same time.
As I said, I don't have a drill press, so I dug out the dremel, went all savage and held it by hand. Switched it on, put the tip against a point and then rotated the key by hand. Repeated a bit higher a few times and the tip was round and centered for sure.
I have to admit that, even if I tried to keep the tool still, some vibration and small movement may have occurred. In fact I had to smooth out the surface with the flat file. Nevertheless, I was sure the key was well round and uniform enough for the precision I need to open this lock.





Even if it's still a bit too long, it's nice to see that it enters the keyhole now. I smoked the tip to get the sliders position and am ready for the next steps: establishing the tip length so the flag enter completely the keyway and cut the bittings on the tip.

Cheers

[femurat]

What a great feeling when the key finally turns!
I wish I went slower with the dremel but couldn't help the urge to finish this key. I still have some marks left, and the hole is not perfectly centered. I'm quite happy anyway. I think I'll keep this as spare key and carefully copy the cuts on the 3D printed one when it arrives.

I hope to start building the box this weekend. I also need to chose the color and material for the inner lining. I'm thinking about Alcantara (Ultrasuede).

Cheers

[kwoswalt99-]

Ooh, what wood will you use?
I can't see the pics, but i'm sure the key looks great.

[femurat]

kwoswalt99-, I'm using pine wood. Why can't you see the pictures? Well, thanks for thinking that the key looks great even without having seen it

I've cut the slot for the lock with a chisel and then made the two big holes with the drill. It still need to be sanded, but after two hours I was tired and hungry. Will refine and glue it next time I have a free hour or two. I need to buy and cut another piece of wood for the cover. I also need some matching screws.

Cheers

[femurat]

So I was cutting the two slots for the hinges and the first one was looking good. Then while I was finishing the second one I probably hit the chisel a bit harder than I should have, because the wood split badly. I was frustrated and left it alone. I may try to glue it back. I'm not so willing to cut another back panel from scratch.

Cheers

[zeke79]

Unfortunately pine splits easily when chiseling as you have discovered. The work looks great so far! I can't wait to see it finished!

[femurat]

I tried to glue the piece back in place so I lifted it slightly and put some glue in the crack. Then put a piece of plastic around it and clamped between two other pieces to keep it straight. Then I added another clamp on top (not pictured) and let it dry overnight.





This morning I took the clamps off and, to my surprise, it looks like new! I just need to clean the glue that squeezed out.

Cheers

[femurat]

I sanded and glued the box, then mounted the lock and the hinges and strike to the lid. The box is starting to assume its final form.
Took it apart again and gave it the first coat of paint. It'll look like light walnut wood once finished.

Cheers

[zeke79]

Beautiful work!

[femurat]

The 3D printed key arrived yesterday. This morning I was so excited I woke up at 5 so I could file the bittings without my girlfriend noticing.
First of all I smoothed the hole on the tip by hand: I rotated a drill bit with my fingers against the hole a few times. This should help centering the key.
I carefully filed the slots with the needle file, copying the steel key, but left them a bit shallow. Then I finished them one by one while checking the key every few strokes. Now the key works very smoothly.

Now I need to find a place that can chrome it to protect it properly.

Cheers

ps: thanks zeke