This is Courtesy of marso, and our FAQ thread
Making your own picks: (By PYRO1234321)
Ideas here are not exclusive. they are a conglomeration of various opinions and experiences gathered on the lockpicking101 forum and other sources online.
locked/Making_Picks_1.wmv - Best source of info
http://www.gregmiller.net/locks/makelockpicks.html - Basic overview on making picks
Can you use a paperclip/bobby pin?
Yes, but with poor results. a modified bobby pin would be preferred to a paper clip, the metal is soft and might work in a pinch. Frustrating to try and learn with these tools/materials due to them bending and being of the wrong sizes. Flattened nails and clotheshanger also fit in this category.
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What can I make picks out of?
Suitable materials in order from worst to best (IMHO, very hard to order): leaf rake fingers, wiper-blade inserts, street cleaner bristles, oil/transmission dipsticks, stainless steak knives (vary), straight saw blades (hack, jig, etc..)(vary a lot). unclassifiable Custom spring/carbon steal or exotics like titanium. wrenches are made from the same.
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What is the best material?
By including price and ease of manufacture, i would say that saw blades are the best. Blade prices and characteristics are extremely variable. get a few and test, some are very fragile. Also look for blades that are close to the desired size to minimize grinding. for free, use wiperblade inserts, street cleaner bristles or steak knives.
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How do I make picks?
Tools: bench grinder, sand paper (medium and very fine), demel tool (cut-off wheels, stone wheels), propane torch (for twists, not always necessary), a hot plate (as a substitute ot a torch), bucket of water (to cool the metal down).
Templates can be found online (online stores, pick manufacturers, forums), transfer to metal and grind, sand smooth, test and modify if needed.
viewtopic.php?t=55 - Discussion on Making picks
http://www.crypto.com/photos/misc/picks/ - Example of a possible template
What handles should I put on my picks?
handles are a matter of personal preference and imagination. some options are: none, tape, heat shrink (or both), extra layes of metal either glued or brass rivited. glued wood (ie: popsicle sticks) to both sides then groud/sanded to proper size, dip into various tactile paints/coatings (ie: rubber undercoating).
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