The seemingly straightforward task of key duplication often transforms into a frustrating odyssey, marked by multiple trips and the persistent failure of copied keys to function correctly. This article offers insights and solutions to ensure successful key replication.
The Root of the Problem: Machine Variance and Operator Variability
The core issues stem from the inherent limitations of key-duplicating machines and the operational inconsistencies associated with their use.
- Calibration and Maintenance: Key-duplicating machines, frequently found in hardware stores and similar establishments, undergo calibration at irregular intervals. This lack of consistent maintenance can lead to deviations in the cutting process, affecting the precision of the copied keys.
- Operator Influence: Even on the same machine, different operators may employ varying setup procedures. These procedural differences introduce further variability, potentially impacting the accuracy of the key copies.
- Mechanical Wear: The cutting wheel, a critical component of the key-duplicating machine, experiences wear over time. Additionally, the mechanical components of the machine are susceptible to shifts and movements with use. These factors contribute to variations in the tolerances, making it increasingly difficult to produce a copy that reliably operates the intended lock.
Strategies for Successful Key Duplication
Despite these challenges, there are several strategies that can significantly improve the likelihood of obtaining functional key copies:
- Prioritize Original Keys: The most crucial step is to use an original key when making copies. Using a copy of a copy, or even a copy of a second-generation copy, increases the chances of exceeding the acceptable tolerance levels. This is because each subsequent copy amplifies any existing deviations from the factory-specified cut depths. Utilizing the original key provides the best chance of producing a functional copy.
- On-Site Duplication for New Installations or Rekeying: When new locks are installed or existing locks are rekeyed, it is highly advisable to have extra keys copied by the locksmith on-site. This allows for immediate testing and verification of the copies’ accuracy before the locksmith departs.
- Preserve Key Code and Keyway Information: Keep the code number and keyway (e.g., Weiser, Schlage, Kwikset, USCAN) from the original key on file. This information is invaluable. If the original key is lost or misplaced, a new key can be milled to factory specifications.