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Here is the pictoral for the key modification. By Bryson66, write-up and photos by CeeAre Here is the pictoral for the key mod...Many thanks to Byron66 for the original idea! ![]() Parts required: - Bicycle valve caps from Wall Mart ($2.88) - Duplicate key from locksmith or dealer ($3.00) ![]() - Epoxy (Home Depot, $2.97) - Dremel with cutting wheel (or small hacksaw blade) - Grinder or file - Vise - Rag - Alcohol and/or Acetone - Optional: Drill and assorted drill bits Step 1: Test new key in all locks to ensure operation. Mark depth that key needs to be inserted for proper operation to avoid new key head from interfering with depth. ![]() Step 2: Secure new key head in vise using wood or cardboard to protect finish from jaws of vise. ![]() Step 3: Cut a single slot in key head on side that valve stem would go, being careful to not cut into the adjacent arms of the cross. A hacksaw can be used here, but be careful to not cut too deeply. ![]() Step 4: If the duplicate key you had made is the same size as the OEM key, skip this step. Cut head off of new key, leaving 1/2" extra shaft. ![]() ![]() Step 5: Using a grinder or a file, shape the end of the key to be inserted into the new head to fit comfortably, making sure you have NOT encroached into the 1/2" clearance on the line previously marked. ![]() ![]() Step 6: Mix epoxy on a disposable surface (i.e. paper plate). Use the end of the key itself to mix the epoxy. ![]() Step 7: Insert key into slot and fill the rest of the hole with epoxy using a pop sickle stick or scrap wood to let the epoxy drip into the opening. Clean any excess or spillage with an alcohol or acetone dampened rag. ![]() Ensure key is level and square and that the marked line is still visible. Allow to set for 10 minutes and then reclean the key itself with solvent to make sure no residue exists. Let cure overnight before use. Optional Step: Drill new key head for insertion of ring for fob attachment starting with the smallest drill bit you have and working up to approx. 5/32". ![]() ![]() ![]() The Finished Key
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