DIY Swiss Army Key Holder by BCDesign01

Do you ever have problems finding your most used keys in the bunch you carry? I made this Swiss army key so I know where my most used keys are at all times! I just put it in my work trousers cargo pocket and know its there when I need it!

Watch the video I made for my YouTube channel BCDesign it will help you understand the following Instructable steps!

What you will need:

• Handsaw
• Belt Sander
• Drill
• 6mm Metal & Wood bit
• Hacksaw
• Clamps
• Superglue
• Dremel or half round file
• Jigsaw or scroll saw
• 2 6mm bolts & nuts
• 6mm washer
• 2 keys
• Danish Oil (or other finish of your choice!)
• Sand paper 240 grit

• Lay out your keys on the aluminium and mark their position, making sure to leave room between the shanks of the keys for the washer that will be used as a key stop later.

• Mark the position of the hole in each key, the 6mm bolts will pass through these holes.

• Use a vice or bench hook & clamp to hold the aluminium pieces while you use your hacksaw to cut them.

• Spray some wd40 on the points you marked for the bolt holes.

• Clamp the 2 pieces of Aluminium together and drill the holes at the same time

• Use a drill and the 6mm metal bit to drill the holes, the wd40 will stop the tip of the drill bit from overheating.

• Use something round a similar size to your thumb tip to mark where you will cut the finger grooves on one of the aluminium pieces.

• The finger groves will allow you to grip the keys and open them easily later.

• Use a Dremel and metal cutting bit or file to cut out the finger groves.

• Grind two flat sides on the 6mm washer.

• Test fit the washer between the 2 keys.

• Make sure both of the keys can close against the washer before it is glued in place.

• Mark the position of the washer, apply some super glue and clamp it in place.

• Mark the outline of the aluminium pieces on the walnut.

• Use a jig saw or scroll saw to cut the walnut.

• Lay your aluminium pieces on the walnut and use them as templates to drill the bolt holes in the walnut.

• Use a lollipop stick to spread the superglue on the walnut.

• Insert the bolts through the holes in the walnut & aluminium to make sure the pieces are aligned.

• Clamp the walnut and aluminium pieces together until the superglue is dry.

• Make sure to remove the bolts so they do not get glued into place.

• Use the dremel to grind the walnut around the finger groove to shape.

• Bolt the Swiss army key together & use it to round over all the sharp square edges.

• If you do not have a belt sander you can do this with, you can use files & sandpaper on a soft sanding block.

• Take the Swiss army key apart & give it a final hand sanding.

• Apply a small amount of superglue on the threads of the bolts.

• Use a spanner or small ratchet to tighten the nuts onto the bolts.

• The bolts I used were a bit too long so I used the belt sander to sand them flush with nuts.

• Use a cloth or kitchen towel to apply the danish oil

• Apply 3 coats of oil on the Swiss army tool

• Sand with 240 grit sand paper between each coat of danish oil.

I really enjoyed this project it was quick, fun & is very useful!! The next time I make one I will use flush bolts instead of regular bolts even though I like the chunky design of this Swiss army key!

Check out the video if you didn't at the start of this Instructable & please vote for me with the vote tab at the top of the page if you liked this project!