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How to cut a key

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Arieldouglas
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Reb Stew
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How to cut a key Empty How to cut a key

Post by Reb Stew November 22nd 2012, 1:57 am

This one was hard to swallow. I have never lost a set of keys to anything in my life. Last week I lost my first key ever. The only key I had to the 1954 Chevy Truck. It worked in the door and ignition. The factory key! It was on a thin ring and I guess it broke while I was walking around town. I back tracked the next day hoping to find it but no luck.
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Post by Reb Stew November 22nd 2012, 1:59 am

I started digging around and found 6 old blanks in my keys.
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Post by Reb Stew November 22nd 2012, 2:01 am

I debated posting this on the open forum due to all the want to be Gone in 60 Second guys but I figured someone may need to use this on their own car one day, so here goes.
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Post by Reb Stew November 22nd 2012, 2:02 am

First get a blank that will fit your car. Stick it in and make sure it slides through. Don't force it!
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Post by Reb Stew November 22nd 2012, 2:05 am

After you have the right blank take a sharpie marker and mark where the teeth would be on a key.
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Post by Reb Stew November 22nd 2012, 2:10 am

Take your new key and stick it in the ignition.

You are trying to see where the tumblers are. The tumblers sit at a certain level on your key. When they are all in the right spot the lock will spin. To get them in the right spot you have to cut the notches.


Last edited by Reb Stew on November 22nd 2012, 2:52 am; edited 1 time in total
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Post by Reb Stew November 22nd 2012, 2:13 am

Turn the key back and forth like you are trying to start it and then turn it like you are turning it off. The key will not move. It will feel like it's stuck. What you are doing is working it back and forth to mark where the tumblers are.
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Post by Reb Stew November 22nd 2012, 2:15 am

The tumblers will rub the marker off. Do you see the silver where the red is rubbed off?
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Post by Reb Stew November 22nd 2012, 2:16 am

The first tumbler is way up on the key. This is normal. You can see how high you have to go on the first compared to the others.
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Post by Reb Stew November 22nd 2012, 2:21 am

I have ran into many lock smiths that don't know how to do this but the ones who do use a file to cut their keys. I have done this a few times Very Happy I don't suggest you do it like I did but I used a cut off wheel in a hand grinder. If you do this you have to have a good eye and smooth hands.
Use a small file for the first 100 keys you do then step up to the cut off wheel.
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Post by falconwagon62 November 22nd 2012, 2:21 am

fire it UP!!!!

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Post by Reb Stew November 22nd 2012, 2:23 am

This is the first cut. Just find where the tumblers hit and file up to where the marker is scratched in each spot.
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Post by Reb Stew November 22nd 2012, 2:24 am

falconwagon62 wrote:fire it UP!!!!

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Very Happy
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Post by Reb Stew November 22nd 2012, 2:25 am

Stick the key in. Don't force it! Now that you have cuts in the key the tumblers are not going to flow over the key like before. Just work it in. It will still not turn. This is where you have to be careful.
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Post by Reb Stew November 22nd 2012, 2:28 am

Just make sure you can get the key all the way in. If not you will need to clean up any walled cuts that won't let the tumbler flow over. file more so the tumbler will slide over.
JUST A LITTLE AT A TIME. KEEP CHECKING IT. YOU DON'T WANT TO OVER FILE IT!
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Post by Reb Stew November 22nd 2012, 2:30 am

After it slides in fairly good pull it out and use your marker again.

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Post by Reb Stew November 22nd 2012, 2:34 am

Stick the key back in and work it back and forth again so the tumblers hit the marker.
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See the silver through the red? There is 3 spots.
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Post by Reb Stew November 22nd 2012, 2:36 am

File almost all the silver but leave just a pin tip showing on each tumbler mark. If you over file the tumblers will be off and it won't turn. When you go too far pitch the key in the garbage and get another one.
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Post by Reb Stew November 22nd 2012, 2:39 am

Key is cut more and is sliding in and out better. It still won't turn.
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Marker again.
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Post by Reb Stew November 22nd 2012, 2:41 am

Stick it back in and work it back and forth.
You can now only see two scratch spot.
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Last edited by Reb Stew on November 22nd 2012, 2:57 am; edited 1 time in total
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Post by Reb Stew November 22nd 2012, 2:43 am

Cut, file that scratch. Here is what we have now.
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Post by Reb Stew November 22nd 2012, 2:45 am

Stick the key in and work it back and forth. It took a few times but now the ignition turns. DON'T cut/file anymore! The key will be really sticky. It will be hard to get the lock to turn you will have to wiggle it up and down side to side to get it to unlock. Your cutting is DONE!
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Post by Reb Stew November 22nd 2012, 2:49 am

Next all you need to do is clean up the rough edges. hopefully you will have a wire wheel on a bench grinder. Take the key where you cut it and clean it all up. It may take a few times but this is all you will need. Keep sticking it in the ignition until it turns free. If it sticks just a little you can stick it back under the wire wheel.

You are done and you have a key that works. It may feel a little tight but the more you use it the better it will feel.
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Post by Reb Stew November 23rd 2012, 11:28 pm

That must have been a boring tech.
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Post by 1/2done November 24th 2012, 4:08 am

I don't have any keys for my Studebaker, this will come in handy. Great tech post!
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