CMV
Platinum Member
Don't know if i posted before, but this is what I did to "fix" my ignition key. Due to location, I was continually bumping the key with my knee, bending the key and wallowing out the key slot. Was afraid I was eventually going to break key off in switch. Thought I had better pics on my phone, but apparently not.
I turned down some 7075 aluminum round stock and then knurled the end with a diamond pattern. Then parted it off about .200" thick. Then milled a slot in the center about .125" deep with an 1/8" endmill as long as the key shank width. Cut the key off to where it was just long enough to go in that slot and fully insert into ignition switch. Used some JB weld to secure the cut off key into the slot on the knob. End result was a key a little harder to turn (should have made OD a little larger), but out of the way of my knee. And if I did accidentally bump it (which I never did again with shorter OAL), it would just push the key "in" vs moving it laterally and trying to bend it. Worked really well! Sorry I don't know what I did with the in process pics, but can probably tell enough from description and finished picture below
I turned down some 7075 aluminum round stock and then knurled the end with a diamond pattern. Then parted it off about .200" thick. Then milled a slot in the center about .125" deep with an 1/8" endmill as long as the key shank width. Cut the key off to where it was just long enough to go in that slot and fully insert into ignition switch. Used some JB weld to secure the cut off key into the slot on the knob. End result was a key a little harder to turn (should have made OD a little larger), but out of the way of my knee. And if I did accidentally bump it (which I never did again with shorter OAL), it would just push the key "in" vs moving it laterally and trying to bend it. Worked really well! Sorry I don't know what I did with the in process pics, but can probably tell enough from description and finished picture below
