Another way to deal with a broken key head
 

I've gone through three of the plastic key heads on our CD key. This time I thought I'd use some POR-15 2-part epoxy putty and sculpt a key head.

I spent about 15 minutes and I'm happy with it. It could be made to look better with more sanding and some paint.

Nice job. Could you give us a brief description about how you accomplished this?

Thanks.

I cleaned up the key blade and noted where the plastic head stopped on the blade so I wouldn't allow any putty past that point making the blade too short to fit in the tumbler.

I mixed a small amount of the putty and rolled it out like dough until it was half the thickness of the plastic head. Then I placed the blade on the putty, folded it over and pressed it in. I folded the remaining putty over two more times and shaped the face with a razor blade as the putty started to harden.

I used snips to cut a traced outline and then sanded it as it cured. I used a dremel to grind the hole. Once the putty is completely cured, it's like a rock, so I did all the shaping while it was still kind of rubbery.

I also rested the key blade on 2 utility knife razor blades to allow the blade to be aligned with the thickness of the putty as it cured. I didn't want the key head to cure crooked.

so you don't fear the head snapping off where as at least the plastic/rubber type give you some form of warning in sense of the rubber/plastic tearing a bit.

Maybe if I tried to break it I could, but it's very tough. I have no fears.:D

You could probably do this, with a bit less effort, with the single-part JB SteelStick that comes in stick form. It's fairly hard to start with, but still malleable, and seems to dry rock hard. From experience it would be easy to sculpt.

I should just machine my own w124 key out of stainless since it has that weird cut

Then you could cut the head as a tri-star.:cool:

ok, now I'm thinking of a way to do this...:mad:

When will the Prototype,models be available?
 

I'll spend some real USD for a couple of those.

Aww, just break out the welder. :-)

http://www.peachparts.com/shopforum/2617037-post20.html

The putty looks good though but I didn't think of that.