Step #1: MaterialsPrevNext
Two pieces of wood (about 1" x 3.75" x 1/8" each)
Thin sheet metal (about 2" x 3.75")
Two #8 machine screw lock nuts
Two #8 machine screws, 3/4" long
Ten #8 machine screw washers
Glue that is able to bond wood to metal (not pictured)
Wood stain (optional)
Drill and bit set
Sand paper/sanding block
Small binder clamps
- Source Tips:
Paint stir sticks are a good size to be used for the wood pieces. These are generally free at the paint section of most hardware stores. For the sheet metal, I used a baking sheet that I found at dollar tree for $1. This yields about 13" x 9" of metal.
Step #4: Assemble the FramePrevNext
- Insert the machine screws through the holes in the metal plates. Then add the washers and keys. Four keys and five washers will fit perfectly on a 3/4 inch screw in the sequence (sheet metal, washer, key, washer, key, washer, key, washer, key, washer, sheet metal). Using this sequence, two keys and three washers will fit on a 1/2 inch screw. Likewise, six keys and seven washers will fit on a 1 inch screw.
- Alternatively, you can conserve space a little bit by eliminating the washers, but the keys will tend to stick on each other. If you have an odd number of keys you can fill the space with two washers.
- When you are done adding keys and washers, add the second piece if sheet metal. Then tighten everything together with the two lock nuts.
Step #6: Apply Stain and Polyurethane to the Wooden Panels (optional)PrevNext
- Once the glue dries, your Swiss Army Key Ring is ready to use. But I chose to take it a few steps further by applying stain and polyurethane to make it look a little nicer.
- To apply the stain I just used a piece of cheesecloth. Then when the stain was completely dry, I applied the polyurethane with a sponge brush.
Step #7: Finished Swiss Army Key RingPrevNext
- This design saves space in two ways. First, the keys are mounted parallel to each other and don't fan out. Second, the double folding design allows the blades of both sets of keys to all fit within the space of the handle
- This design is also a better way of organizing keys. Because the keys are always in the same orientation, it is faster and easier to find the key that you need.