Firstly, let me make clear that I like Covert Instruments, they make some good products and I enjoy the content from LPL and McNally. This was a little project I was goofing around with one afternoon and when coming up with a name, thought it would be witty to show some patriotism in climate of the trade war. So without further ado, I present my maple flavoured rip-off of the very clever "Replicant" key casting kit. It features the same interlocking case design that holds the Clam Shell Mould, and a Rolling pin/ powder tube. There is space for a Bic Mini, and if you hit the dollar store you should be able to find a steel measuring spoon which can be modified to fit in the end chambered for it. A classic wristband will hold everything tightly (or a thin belt if you want to make it look even more like a drug kit)

PRINTING: Print it however works best, I made offsets in all interacting parts, I printed the shell with fuzzy skin and everything else smooth in PETG, The Hinge might need some easing in depending on your print quality, but should fit nicely provided your speed it slow enough. I printed The outside case with the flat ends down (supports build plate only), the clam shell with the flat faces down (supports build plate only and the cap and rolling pin with the threads at the top (no supports).

YOU WILL NEED:

Wire/pin for a hinge, the hole is 0.125" but you will want to line the cases up, clamp them lightly and gently ream this out with with whatever drill you have that fits your pin stock best, this will give you the most solid hinge alignment.

Tap and Die set, the thread on the tube is M9x1.25, if you have a great printer maybe it's fine, but I like to clean threads up with a tap and die, they feel much nicer.

Zip disk, for cutting your spoon to size.

Spoon, Bic Mini, Wrist Band, Sculpy, release powder and casting metal.

WHAT IT DOESN'T HAVE: Unless you modify the spoon yourself, it won't have a business end for carving a vent or a serrated edge for clean up, it's up to you for that. It also doesn't have the pass through opening for making the impression, although you can obviously use half the case to hold it upright. It also doesn't have space in the mould for little ingots of woods metal, though there is a cavity to store some material in the spoon side of the case, however unless you are in need of multiple keys, you can just prime the spoon with some molten metal and let it cool before putting the kit together. I haven't cast anything yet, so please give me feedback and opinions and if there's a good enough reason to update the design I will. Casting metal can be found online, but plumber's silver solder also melts with a lighter and as long as you get stuff without flux it won't smoke too bad (just do it outside anyway).

I am always happy to get feedback, let me know if you have any trouble making this, or any suggestions that might improve it. At the moment I think the clam shell mould might benefit from having jaws that index to the correct closed position, and being a bit beefier, but let me know how you get on if you make it.