BG74

I had to drill 2 of the 3 out on mine....

TL1999

I got 1 out of 3...i haven't try drilling it...I guess that will be my next step...I will try it after the game...Thanks...

GO DAWGS!!!!!!!!!!

Black_05_TL_6SP

They will come out. If you have already striped them then you will have to drill.
In order to remove them without completly striping them out, you need the proper phillips bits. They used 2 different phillips bits on the screws that hold the key in. You will need to put something soft under the key, and press down with a lot of pressure and turn. I only had a problem with one of them, but they all did come out without having to drill.

TL1999

Thank you. I got the items apart now I have half of screw in the back piece of the key. Any ideas?

pb1300

Why couldnt we just cut the old key and weld it to the ending of the blank key? would that work?

Black_05_TL_6SP

Its brass, very soft when it comes to welding. Not to mention, the heat generated would melt the plastic it is in. I am going to be working on the mold tomorrow, I hope. I should know by mid-week how it will turn out.

It will be only the blank key attached to the plastic. So for those that have one and have it apart, this would just drop in. It will require a transponder be inserted into it as well. That can be obtained from your valet key or anyone of the keys you have. Or it can be cut out of the one you have from the switchblade key and programmed to the car at the dealer.

Black_05_TL_6SP

Post a pic of it if you can. I would need to see how much is left of the screw.

carpecervisi

When tidus888 first posted this idea (I think he was the first) it kind of intrigued me. I was thinking along a different line though:
1. Cut the 07 blank about .35" from the plastic
2. Cut the 07 blank stump so the 04-06 blank would be sandwiched between like so:

If you could make those precision cuts, then you could weld the blanks together somehow...just a thought. And probably a stupid one at that.

-chad

DeadLock

I really think welding is a bad idea.

Any new updates with milling the key blank down to work like the 04-06 key?

tidus888

The WIDTH is different as mentioned before!

Kash

I explored the cutting and welding idea over the weekend and it is a bad idea.
1. Most likely the heat will melt the plastic.
2. Even if you can somehow manage to weld the two (shaving the 07 key to match the width of the old key before the weld ofcourse) there is a very strong possibility that the key might break in the ignition switch.

I am planning to take the 07 key fob apart and see if I can find another way.

FLBusa

GOT MY KEY TODAY!!!!!!

We'll see what the next couple of days brings.

I'll keep you guy posted.

FLBusa

I think you're on the right track Chad. I wouldn't weld it though... I'd use a solid rivet. If you drilled say an 1/8" hole through both parts while they were assembled and then counter sunk holes, you could then insert a soft stainless or brass pin that was a little bit longer than the thickness of the two parts and peen (hammer) the pin ends so that the squashed pin would fill the counter sink.

No welding... no glue... and would never come apart.

Butler230

iTrader: (1)

Good luck FLBusa!

I know we are all anxious to see your skills put to work on this project.

lembowski

iTrader: (1)

Those screws are a bitch to get out. I go 2 out, but one will not budge. Its the shortest of the three, and its almost stripped. I need to find a flat head screw driver that fits to utilize the two good threads left. What are my options if I can't get it out? I saw where you guys said drill it out, whats invloved in that? Can I do it with a dremel?

Bob289

You can use an easy out kit. Not to expensive. First you dill out stright thru the center of the screw. Then using the easy out you screw the bit backwards ( its reversed thread) and as you tighten the bit the easy out groves will grab onto the screw and come out. Being its a screw on the 07 fob your trying to mod im not too sure if they make easy outs that small. You can check your local hardware store and see if they have them.

carpecervisi

Yeah, for whatever reason that third screw, the silver one, is a real bitch. The other two have thread locking gunk on them so they are a little tough to get out, but the silver screw I ended up getting a small drill bit and literally drilling out the head of the screw.

I guess if you have the right dremel bit and are very careful, you could use one. Good luck.

-chad

lembowski

iTrader: (1)

How will you get the threads out? Will it be difficult to find a screw to fit back in there when you put it back together?

jptl04

iTrader: (1)

use this precision screwdriver, i got it at home depot for $5 works really good. i got mine out no problem, place the key on a flat surface, put something soft like a towel under it, apply a good amount of presure, almost as if you are leaning all you upper body on the screwdriver and turn, they come out, and you wont strip any of them

csmeance

is anyone still trying to find out if the 07 blank can be machined to the 04-06 blank by a CNC/Mill?

Black_05_TL_6SP

My uncle is working on creating the mold for the replacement key. I hope to have something tangible by the weekend. I will keep everyone posted to my progress with this project.

Jason

FLBusa

There's no question that it can be milled to duplicate the '06 and lower keys. I'll keep everyone posted on my progress.

Pete

lembowski

iTrader: (1)

So its width is good enough to make the 90 degree stops?

yuhoo22

Pete, that is great news! I'm still on your list right?

tidus888

are we suppose to take the screw on the top out of the 07 key to take it apart?

tidus888

can someone post instruction of how to disassemble the key?

nyctl

dude
it's been posted already in this thread

FLBusa

As promised... Here's an update on my progress with machining the key.

First and foremost I had to machine a test key out of aluminum before I committed the '07 key.


First I cut down a piece of 1/2 x 3/16 aluminum stock to match the width of the '07 key and the thickness of my '06 key.


Next I cut the small grooves. Since the key is radially symetrical I just have to open the vice, flip the blank and cut the groove on the opposite side.


Prototype with completed grooves.




Next I cut the thin blade portion and the small step that acts as a stop for the key.
Once again... flip the key in the vice and let it rip.


Last part was to grind the tip angles and deburr the key.






Now to take it outside and test it...
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.

Viola!!!! The key blank went in like it was a part from a swiss watch.







Funny thing though... At first it wouldn't go into the ignition.
Then I pulled out my key and held it next to the prototype key and it slid right in.
Darn imobilizer chip... good to know that you have a little bit of added security though.

Next... The '07 key.

subinf

^ - that is really sweet. good luck with the 07 key.

AcuraTL06

WOW!

That looks like A LOT of trouble for the key...

But props to you. Good job!

FLBusa

The prototype lets me know with 100% certainty that the next 500 I do will work.
...and I won't settle for anything less than perfect.

It also gives me an opportunity to create a setup on the mill.

Total time to setup and make the prototype was 3 hours. Time well spent IMO.

csmeance

FLbusa, if you can get a complete key (unlock/lock/trunk/key/immobilizer) in driver 1 that the dealer can program for me, i'd be one of the first to buy them, where do i pay?

FLBusa

That's the idea.

Just PM me.

I still have a way to go. ...still need to get a custom cutter and some quick change tooling going.

studville

What exactly is a precision screwdriver. And what is the difference between it and a regular screwdriver?

tidus888

Hey good job there! do you mind posting the exact dimensions of the org key?

and what size drill bit did you use to cut the grove?

tidus888

i am planning to cut the 07 blank monday to see if it works or not with the slimmer width =)

FLBusa

Well... That's pretty presumptuous.

No disrespect here but...

You're on your own chief...



Let me know how things work out for ya.

ps... Don't forget to measure twice and cut once.

FLBusa

As funny as it sounds... Those are precision screw drivers. They're machined to much tighter tolerances so that they fit the slot without any play. That way you can apply considerable torque to the screw without the head stripping.

The Dougler

iTrader: (1)

Nice work, i cant wait to see the final product, hopefully it works out! Im down for one.

triggle

FBusa,
Nice work. Looks promising.

Is aluminum the material of choice or just a beta test ? There will be allot of leverage on the key if it has a FOB attached to it so it will be easier to break.

I am not a locksmith but there must be reasons why they use brass and aluminum keys. Would a stainless key be too hard on the ignition ? At least it would be strong.