The hard part of making a torque wrench is bending the bristle withouth cracking it. To make the 90 degree handle twist, clamp the head of the bristle (about one inch) in a cise and use pliers to grasp the bristle about 3/8 of an inch above its vise. You can use another pair of pliers instead of a vise. Apply a 45 degre twist. Try to keep the axis of the twist lined up with the axis of the bristle. Now move the pliers back another 3/8 inch and apply the remaning 45 degrees. You will need to twist the bristle more than 90 degrees in order to set a permanent 90 degree twist.

Figure A.1: Selection of pick shapes

To make the 80 degre head bend, lift the bristle out of the vise by about 1/4 inch (so 3/4 inch is still in the vise). Place the shank of a screw driver against the bristle and bend the spring steel around it about 90 degrees. This should set a permanent 80 degre bend in the metal. Try to keep the axis of the bend perpendicular to the handle. The screwdirver shank ensures that the radius of curvature will not be too small. Any rounded object will work (e.g. drill bit, needle nose plies, or a pen cap). If you have trouble with this method, try grasping the bristle with two pliers separated by about 1/2 inch and bend. This method produces a gentle curve that won't break the bristle.

A grinding wheel will greatly speed the job of making a pick. It takes a bit of practive to learn how to make smooth cuts with a grinding wheel, but it takes less time to practice and make two or three picks than it does to hand file a single pick. The first step is to cut the front angle of the pick. Use the front of the wheel to do this. Hold the bristle at 45 degrees to the wheel and move the bristle side to side as you grind away the metal. Grind slowly to avoid overheating the metal, which makes it brittle. If the metal changes color (to dark blue), you have overheated it, and you should grind away the colored portion. Next, cut the back angle of the tip using the corner of the wheel. Usually one corner is sharper than the other, and you should use that one. Hold the pick at the desired angle and slowly push it into the corner of the wheel. The side of the stone should cut the back angle. Be sure that the tip of the pick is supported. If the grinding wheel stage is not close enough to the wheel to support the tip, use needle nose pliers to hold the tip. The cut should pass through about 2/3 of the width of the bristle. If the tip came out well, continue. Otherwise break it off and try again. You can break the bristle by clamping it into a vice and bending it sharply.

The corner of the wheel is also used to grind the tang of the pick. Put a scratch mark to indicate how far back the tang should go. The tang should be long enough to allow the tip to pass over the back pin of a seven pin lock. Cut the tang by making several smooth passes over the corner. Each pass starts at the tip and moves to the scratch mark. Try to remove less than a 1/16th of an inch of metal with each pass. I use two fingers to hold the bristle on the stage at the proper angle while my other hand pushed the handle of the pick to move the tang along the corner. Use whatever technique works best for you.

Use a hand file to finish the pick. It should feel smooth if you run a finger nail over it. Any roughness will add noise to the feedback you want to get from the lock.

the outer sheath of phone cable can be used as a handle for the pick. Remove three or four of the wires from a length of cable and push it over the pick. If the sheath won't stay in place, you can put some epoxy on the handle before pushing the sheath over it.

3. Bicycle Spokes

An alternative to making tools out of street cleaner bristles is to make them out of nail and bicyle spokes. These materials are easily accessable and when they are heat treated, they will be stronger than tools made from the bristles.

Figure A.2: Torque wrenches

A strong torque wrench can be constructed from an 8-penny nail (about .1 inch diameter). First heat up the point with a propane torch until it glows red, slowly remove it from the flame, and let it air cool; this softens it. The burner of a gas stove can be used instead of a torch. Grind it down into the shape of a skinny screwdriver blade and bend it to about 80 degrees. The bend should be less than a right angle because some lock faces are recessed behind a plate. (called an escutcheon) and you want the head of the wrench to be able to reach about half an inch into the plug. Temper (harden) the torque wrench by heating to bright orange and dunking it into ice water. You will wind up with a virtually indestructible bent screwdriver that will last for years under brutal use.

Bicycle spokes make excellent picks. Bend one to the shape you want and file the side of the business end flat such that it's strong in the vertical and flexy in the horizontal direction. Try a right-angle hunk about an inch long for a handle. For smaller picks, which you need for those really tiny keyways, find any large-diameter spring and unbend it. If your careful you don't have to play any metallurgical games.

4. Brick Strap

For perfectly serviceable key blanks that you can't otherwise find at the store, use the metal strap they wrap around bricks for shipping. It's wonderfully handy stuff for just about anything you want to manufacture. To get around side wards in the keyway, you can bend the strap lengthwise by clamping it in a vice and tapping on the protruding part to bend the piece to the required angle.

Brick strap is very hard. It can ruin a grinding wheel or key cutting machine. A hand file is the recommended tool for milling brick strap.

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