Cutting Warded Keys

Jason Jones

Locks with Box wards, how did they make the keys fit that tight on the warding and help pictures or advice would be great, normally I would just keysaw or mill them out

Pschiffe

I’m not sure what you mean by “box wards” but other than by hand, on a Minute or Turret type duplicator; both long obsolete, see images attached. These were made by Keil and/or Ilco back in the day. There are still some import machines available which have similar functionality.

Pete Schifferli

Syd Waterman

Pschiffe wrote
I’m not sure what you mean by “box wards” but other than by hand, on a Minute or Turret type duplicator; both long obsolete, see images attached. These were made by Keil and/or Ilco back in the day. There are still some import machines available which have similar functionality.

Pete Schifferli

Hi Pete.
Example of a “Box of Wards” lock attached.

Patent.

[unknown]

Jason Jones

I have a normal mortice that can cut side wards etc… Im on about the internal cuts that with a keysaw would be straight cuts, the older ketys were made with round cuts, I have been informed that these were with small chisels

Pschiffe

Patent wrote
Hi Pete.
Example of a “Box of Wards” lock attached.

Patent.

That type of cut could likely be made by a “sidewinder” key duplicator, essentially a small vertical mill; of which there are numerous extant makes and models, see image. Usually used to cut high security auto or the old Bell or Dudley style keys.

Pete Schifferli

[unknown]

Doug MacQueen

Here are two keys fairly close in vintage. In the one the curves were clearly chisel cut but I didn’t get a good clear photo. My best guess on the other key is that it was investment cast. Very little in file or saw marks are seen on the insides of the warding. Doug

Paul Prescott

Jason Jones wrote
I have a normal mortice that can cut side wards etc… Im on about the internal cuts that with a keysaw would be straight cuts, the older ketys were made with round cuts, I have been informed that these were with small chisels

Yes, curved chisels were used. I saw a video once (maybe from the lock museum ???) or two guys (each about 90 years old). They made their own chisels and used small steel wedges to stop the key breaking in the vice while they cut it.

[unknown]