Multipick Key Duplication System

[ratlock]

Heres a few pictures of my efforts key casting. I used an old cigarette case, with a bit cut out the end.
Fill the inside on both halfs with plasticine, as a backing for the silicone.

Use dental silicone that sets in around a minit. Put half the amount of mixed silicone into both halfs, and pat it roughly flat.
Ive then put some graphite dust onto the silicone on both halfs, as a relese agent.

Put the key in and close. Leave to set.

Remove key. Then your ready to pour.

Ive used woods metal, Rose metal, cerrelow 117,and even old wheel balance weights. They all worked. Im going to try gallium next.

[ratlock]

This is how I did it really on the cheap.

[Silverado]

With the incredibly low melting point of gallium, how are you going to handle it to put it into a keyway before it liquefies? I've heard there is a way to solidify gallium...
Honest question out of curiosity I'm not being a smart alec.

[ratlock]

Ive bought a metal and glass syringe off ebay, to suck it up.

Ive not tried it yet, so dont know how well it may ot may not work. It swells when it hardens, so wont work for keys with tight tolerances.
Im not sure how hard it is when set, so may cast a wiper blade insert into the mould, to act as a tension wrench.

Win lose or draw. I will let you know how I got on when the metal arrives from ebay.

[Silverado]

Great! I am looking forward to hearing your results. Thanks!

[huxleypig]

That 2 part epoxy is awesome stuff, I have used it a lot for various things in the past. In particular, making molds. I can stand a higher temperature than you would think and sets very finely and quickly. Cool stuff.

When you are removing the key, I take it that you are opening up the two halves of the silicon impression?

[ratlock]

Yes It opens up in two halfs. I initally tried silicone lube as the release agent. But it didnt work too well. I then used graphite dust lightly put on both surfaces of the silicone putty, just before closing the mold, and this works a treat.

[ratlock]

Here is a ERA 5 lever copied with woods metal.

[huxleypig]

Nice, it's The Great Train Robbery all over again.

[ratlock]

Tried Gallium today. Had problems getting it to run into the mold, as it was cooiling too quick, and not filling properly.

Because it expands when it cools it was too tight in the lock, and the best key I managed (after 5 fails) only needed a touch filed off it. I dropped it by accident, and it broke when it hit the ground. So too brittle for any practical use.

It works well in a syrnge, and can be eaisly sucked up from a bowl of water. But not much use for key casting.

[ratlock]

Here is a quick video on key casting. I wouldnt try the galium as a go to metal. The woods metal worked first time, every time for me.
I usually heat the metal in an old ladle using a blow lamp, (didnt show this on the video for lack of time).
This casting methode works well, easy to use, and cheap.
Enjoy the video.

https://www.youtube.com/watch?v=tLiwvRdeNk8

[kwoswalt99-]

Nice little Record vice you've got!

[ratlock]

Yep Its a record 00. Good for making pick wires too.