Car Key Copier

Requirements:

• Dremel (with 3/4-12 threads - this can be easily edited in the Fusion360 file)
• 1.5mm end mill
• 1.5mm drill bit
• Drill (to clean out the small hole in the top)
• Various screws

This is a car key copier that I made in Fusion 360. I'm including the Fusion 360 .f3d file for anyone who needs to remix it. I would NOT recommend any support, as it is not required and may result in a bad installation.

To assemble, you will need:

• 4 screws to secure the top to the frame (I used wood screws 40mm long and 4mm in diameter).
• 2 screws to secure the clamp to the slide (I used sheet metal screws 7mm long and 3mm in diameter).
• 4 screws to securely attach the frame to the wooden board (I used wood screws 25mm long and 4.5mm in diameter).

Important:

1. Before putting it all together, take a drill and a 1.5mm drill bit and drill a hole in the top of the cow’s teat looking object. Then take out the drill bit and insert it into this hole with the hard end of the shank hanging down. Be careful not to bend or break the drill bit, as it is fragile at such a small size! It will be a little difficult to insert, but use pliers to tighten it. You don't want it to be too easy to insert because it needs to be secure and not move when you cut the key. When you're done, use the pliers to unscrew it to pull it out.
2. This device requires fairly good precision. You want the sled and track to glide smoothly without wobbling. Any well-tuned printer can get great results if you do the following: Print the track and, if it needs adjustment, adjust the Y scale just a little up or down until the sled fits perfectly. Then check how it fits into the dovetail frame. If it needs adjustment, change the X scale only until it is perfect. Alternatively, you can cover it with aluminum foil.