How to Make a Key for Metal Cabinet AL15

Making a replacement key for a metal cabinet like the AL15 model can seem daunting, but with the right tools and a bit of patience, it can be done by most DIYers. Below is a step-by-step guide on how to make a working key for a metal AL15 cabinet lock.

Gather the Necessary Materials

Making a key from scratch requires a few specialty tools and materials:

• Key blank – You’ll need a compatible key blank that matches the AL15 cabinet lock. Look for an SC1, SC2, or SC4 key blank. You can purchase these at most hardware stores or online locksmith suppliers.
• File – A flat, smooth file is needed to shape the key teeth. A jewelers file or needle file works best.
• Calipers – A good set of digital calipers are useful for precisely measuring the existing key.
• Marking pen – To mark the cuts on the key blank.
• Sandpaper – Fine grit sandpaper to smooth out the new key when finished cutting.
• Magnifying glass – Helps to inspect the key cuts. A jeweler’s loupe or magnifying glass works well.

Examine the Existing Key

Take the original working key that operates the AL15 lock. Examine it closely using the calipers and magnifying glass. Note the following:

• Overall length
• Location of the shoulder stops
• Spacing between cuts
• Angles and depths of each cut

Use the calipers to precisely measure the length from the tip of the key to the first cut, and the spaces between each cut thereafter. Mark these measurements on a piece of paper for reference later.

Also note the angle of each cut – whether they are cut straight across, angled forwards or backwards. The angle of the cuts is important when filing the new key.

Mark the Key Cuts

Take the new compatible key blank you purchased for the AL15. Use a marker to mark the measurements from your reference onto the blank key.

Mark the overall length, the spacing between cuts, and also make small lines at the edges to indicate the angle of each cut. This marks out where you’ll need to file the key teeth.

Be as precise with the markings as possible, using the calipers to double check. Accuracy is vital for the key to work properly in the lock.

File the Key Teeth

With the markings completed, you can begin filing the key teeth onto the blank. This is a slow, methodical process that requires patience.

Start with the first cut at the pointed end of the key. Use the file to cut a notch at the marked line, angling the file to match the desired angle for that cut.

Work carefully and remove a small amount of metal at a time, frequently comparing to the markings. Cut all the way through the blank at the correct width and angle.

Repeat this for each subsequent cut, using the file to cut progressively deeper notches aligned with the markings. Apply medium pressure and use smooth strokes for best control.

Periodically place the key blank into the lock cylinder and test that it aligns at the shear line. The key should progressively work its way deeper into the lock as you cut each notch.

Fine Tune the Cuts

Once all the initial cuts are filed to depth, test the key in the lock again. If any cuts feel too tight or loose, you may need to fine tune them by removing a little more metal or smoothing the edges.

Work methodically and only remove a small amount of material at a time to sneak up on the correct fit. The key needs to slide smoothly into the lock, aligning the shear line properly.

Use the magnifying glass to inspect that the cuts match the original key as closely as possible in width, angle and depth. Fine tune as needed with the file.

Smooth and Test Key

When the key slides smoothly into the lock and turns correctly, it is nearly complete. As a final step, smooth any rough edges on the key’s teeth with fine grit sandpaper.

Test the working key in the lock repeatedly, turning it fully to operate the cam and latch. The turning action should be smooth without any sticking or binding.

If needed, you can touch up the cuts again with the file to perfect the fit. Take your time and work slowly and carefully for best results.

When finished, you should have a fully functioning replacement key made from scratch for your AL15 metal cabinet lock. Keep the spare key in a safe place in case the original gets lost or damaged.

Tips for Success

Making DIY keys takes patience and attention to detail. Here are some helpful tips:

• Work slowly and make small cuts at a time for precision.
• Frequently compare to the original key as you file.
• Keep your file blade smooth for optimal control.
• Check your progress frequently by testing in the lock.
• Fine tune any tight or loose cuts for a perfect fit.
• Smooth the teeth and edges completely with sandpaper when finished.
• Always keep spare keys in separate secure locations.

With the right tools and techniques, you can cut a replacement key for most cabinet lock keys, including the AL15. Just take your time and double check measurements for best results.

Frequently Asked Questions About Making AL15 Keys

Making your own replacement keys seems like a daunting task. Here are answers to some common questions about the process:

What kind of key blank do I need for an AL15 cabinet lock?

You’ll want to purchase either an SC1, SC2 or SC4 key blank to match the AL15 lock. Take the original key to the hardware store to identify the correct blank.

Can I just copy the original key at a locksmith or hardware store?

Yes, having a duplicate key copied by a professional locksmith is an easier option than making one totally from scratch. They have key duplication machines to cut a precise copy.

What’s the best way to measure the original key for markings?

Use a good set of digital calipers to precisely measure the length, spacing, and angles of the cuts on the existing key. Copy these measurements exactly onto the new blank.

What file should I use to cut the key teeth?

A smooth, flat jewelers or needle file works best. The key is metal, so take care not to use too coarse of a file texture. Go slowly with a fine file.

How can I tell if my cuts are accurate?

Test the key repeatedly in the lock as you go. It should progressively slide deeper into the lock cylinder. If any cuts feel stuck, they likely need more filing to match the original key.

What’s the best way to smooth the edges of the finished key?

Use fine grit sandpaper (400+ grit) to smooth out any burrs or rough spots on the key cuts and body. This helps the key work smoothly.

How do I ensure my homemade key lasts?

Work slowly and double check all your measurements for accuracy. Smooth the edges very well so the key works cleanly in the lock without getting stuck or jammed over time.

Making your own replacement keys is very satisfying and can get you out of a jam if your only key is lost. Just be patient and precise in your work. With practice, you can learn to recreate keys for all your locks.

Conclusion

Making a replacement key for a metal cabinet like the AL15 is a manageable DIY project that can save you the hassle and expense of calling a locksmith. With some basic tools, a steady hand, and the techniques outlined here, you can create a working duplicate key using an appropriate key blank.

The process involves carefully measuring the original key, transferring those precise measurements to a compatible blank, slowly and methodically filing the notches for each cut, and fine tuning the key for a smooth fit in the lock’s cylinder. Patience and attention to detail are essential. But with some practice, you can become adept at making duplicate keys.

Knowing how to cut your own keys means you always have a backup handy if your original key gets lost or damaged. And you save money by not having to replace entire locksets. Understanding lock keys also gives you a greater appreciation for the intricate engineering that goes into seemingly simple devices like cabinet locks that you use everyday.

So don’t despair if you break or misplace the only key for your file cabinet or toolbox. With a few tools and the skills picked up here, you can avoid paying for an expensive emergency locksmith callout simply to get a replacement key cut. The ability to make your own keys quickly and cheaply is an invaluable DIY skillset for any homeowner or handyman.