PREP

  1. Remove band and set aside lighter (not included), Woods metal, and utility spoon
  2. Open case and remove casting mold and open clay
  3. Take one section of clay and fill one side of mold. Use the roller to flatten and smooth clay. Repeat on other side
  4. Roller doubles as container for release agent such as baby powder (not included). Put a light coating of release agent on clay to prevent sticking.
  5. Place three Woods metal cubes in mold slots. Close mold and place parts back in case.
  6. Use branded band to keep spoon and lighter (not included) to bottom and top of case

MAKING THE MOLD

  1. Remove band and set aside spoon and lighter.
  2. Open prepped mold and remove a single cube of Woods metal.
  3. Place key you are impressioning lightly (do not press key down) on top of clay. Close the mold over the key. Place closed mold back in the case. This helps add compression.
  4. Remove mold and open slowly. Gently remove key from clay. Inspect impression.
  5. Add air channel with the pointed end of spoon from tip of impression to the top of the clay. Press down some of the clay near the top to form a small funnel into the clay.
  6. Close mold and place back in half of the Replicant case with the open side of the mold facing upwards.

MAKING THE KEY

  1. Place spoon in the slot on the bottom of the roller. The roller becomes a handle for the spoon.
  2. Place one cube of Woods metal in spoon. Using lighter (not included) melt cube entirely. Heat for an additional 10-15 seconds after it has melted all the way.
  3. CAUTION: Do this in a well ventilated area and wash your hands after handling Woods metal!
  4. Carefully, and slowly pour melted Woods metal into top of mold.
  5. Wait a few minutes until metal has completely cooled and hardened.
  6. Slowly open the mold and inspect key. There will be some touch up required. Use the serrated side of the spoon to file away any ghosting or edges that need to be cleaned up.
  7. Try the key and make any necessary adjustments. Turn key gently as Woods metal is still fragile and can break off in the keyway. Do not use on an actively used lock.