Some time ago I tried to make a steel key for the dial blocking lock. I didn't want to ruin the lock by impressioning it so I opened the lock and filed a flat piece of steel to match the six levers. It looked right but when I put the lock cover back it no longer worked. Looks like I filed down some position too much and/or I wasn't holding the key perpendicular to the levers when I took measurements. I was disappointed and put everything back in the drawer.
Recently had some time to play with this lock again and decided to make a temporary aluminium key just to be sure about its bittings. Once the key works I'll copy it on steel or, even better, brass. Here are the non working steel key and the aluminium blank I made.
I've inserted the blank and tried to turn and got some impression marks on the side. Those are somewhat related to the right bittings but it's not a good idea to file to those depths. For example the sixth lever doesn't require the key to be filed, but still marks it. You can see the mark on the finished key.
Since I had the lock disassembled I put back one lever at a time and filed just on that spot until the key turned freely and opened the lock. This way I could file and test one position at a time without the risk to file too much as I did with the steel key. I used a hacksaw to file down aluminium since it can easily clog files.
Here is the finished key next to the lock and on a ruler with cm and inches for my non metric friends.
I know the key looks very poorly made and I apologize for this. Keep in mind this is only a temporary key and I'm planning to make a better looking and longer lasting one. Don't hold your breath since I've got not much free time lately so it could take a while. But I do want to finish this project.
Cheers