Setting up a Keyboard

May 4, 2015
Because most locksmith shops maintain a stock of up to 1,000 different key blanks, organization with room for expansion is essential

The keyboard has long been the life's blood for a locksmith shop and service vehicle. Providing easy access, visual stock status and the ability to expand, the keyboard lets locksmiths know key sales direction instantly.

There are upwards of 7,000 different key blanks.  This includes commercial, residential, utilities and vehicular key blanks. Most locksmiths maintain a stock of 1,000 or less different key blanks. Even a thousand key blanks presents a significant challenge to have each number easily available for duplication or origination.

Locksmith shops seen in photographs from the early 1900s show key blanks organized on the store walls. Generally, the key blank boards are mounted onto the exterior walls; starting at about waist height and going upwards. The black and white photo is one of the S & S Locksmith's keyboards, measuring 24 feet long and eight feet tall. According to the grandson of the owner, more than 400,000 key blanks were on this board when fully populated.

Early locksmith shops sometimes extended keyboards up to the ceiling. Today, most appear to be about four feet tall, using standard plywood, slotted panel or pegboard that is probably four feet by seven or eight feet. Slotted panels have a horizontal, non-inserted grooves that are spaced vertically at three inches. The slotted panels can accommodate hooks that are slid in from the sides, so no drilling of mounting holes. The hooks have no vertical adjustment; however they have horizontal adjustment to as close together two hooks can be placed. Pegboards offer holes pre-drilled at specific increments. A common measurement is one inch on center spacing. Using plywood requires measuring, drilling pilot holes and screwing in hooks.

If wall space behind the counter is limited, there are a number of alternatives. Some locksmith shops use revolving carousels made from either four- or six-sided revolving keyboards. These carousels provide additional surface area for key blanks without requiring as much wall space. In addition, carousels can be located in front of large windows, providing double-duty as additional key blank space and blocking the window in an interesting fashion.

Another alternative to wall-mounted keyboards is a rotating keyboard system, with each attached to a vertical rod. The rods are free to rotate permitting the keyboards to swing exposing both faces. This arrangement significantly increases the number of key blanks that can populate an area.

Minimum square footage required for the keyboards is determined by the number of key blanks the shop or service vehicle needs for conducting business and, in the case of the shop, providing sufficient room for expansion as new key blanks are introduced.

To determine the square footage, it is important to know the type and size of the different key blanks. Remote head/integrated and larger head automotive key blanks require additional space. Some handicapped, custom head or neuter bow key blanks have a larger head. Flat steel and keys for safe locks range in length. The longer the keys, the more space they will require.

Square bend screw hooks can be threaded into plywood, permitting multiple hole positions for different length key blanks. Threaded hooks have other advantages; they will not easily be removed from the keyboard and they are cheaper than peg hooks.

Metal peg hook lengths are available from 1.5 inches to 12 inches using either one or two holes for mounting. The two-hole metal peg hook base, designed for one inch on center spacing, is about 1-1/2" wide. The bent wire angle hooks use two vertical holes, having 1.5" length for key blanks. In addition, there are double hooks.

For some popular key blank numbers, locksmiths sometimes add a second hook or keep 250-blank boxes beneath the counter where the key machines are located. Pro-Lok sells plastic key hooks in a variety of colors that accommodate 25-30 key blanks. These hooks have a return on the tip the helps to prevent spilling.

Just as a comparison, the hooks in the black and white photo held 62 metal head keys. That length of hook is not needed today, except for the few extremely popular residential, commercial and utility key blanks.

Once we determine the number of hooks and the square footage of the keyboard, we must decide where it should be placed. The major limitation is the keyboard is normally placed behind the key machines, having limited cabinetry to ensure key blanks are within easy reach.

Carousel keyboards can be installed on top of a cabinet, as additional depth is required for the panels to be able to rotate. An advantage of the cabinet-mounted carousel keyboards is that boxed key blanks can be kept in storage, right under the keyboard for easier re-stocking.

A suggestion: place a key tag behind each hook to label which key blanks are held by what hooks. As an alternative to making your own, Pro-Lok sells white and fluorescent key tags for commercial and automotive key blanks.

OK, we now have our keyboards in position. How do we arrange the key blanks? There are many different ways to populate keyboards. The most common start appears to be separating automotive key blanks, safe deposit key blanks and specialty key blanks such as keys designed for safe locks, luggage, bit and barrel and flat steel from the cylinder key blanks. When I setup keyboards, I combine the North American and the International Cylinder key blanks as they are all cylinder key blanks.

Once the key blanks categories have been separated, the next step is to determine how to organize them. There are several ways including alphabetically by manufacturer or using an aftermarket key blank manufacturer’s numbering system.

If using lock hardware manufacturers’ names to populate the cylinder key blanks on the keyboard, the easiest way to obtain a list is to use aftermarket key blank manufacturers’ catalogs. The manufacturer with the most key blank numbers would give the widest range. I would cross-check multiple key blank manufacturers and lock manufacturers web sites to ensure I have all of the key blank numbers important for my location and customers. For example, I would use the latest Ilco catalog, using the North American Cylinder section as a start. I would create a list. The keyboard would probably begin with Ace and continue through Yale. I would then check the International Cylinder sections and pick the manufacturers whose key blank I sell.

Each manufacturer has their key blanks listed. For example, American Lock, the padlock manufacturer (owned by Master) has nine key blank numbers for single- and double-sided key blanks. Corbin/Russwin has more than seven pages of key blank numbers. To complicate matters, according to Ilco, Adams Rite has seven key blank numbers. However, included in the seven are key blanks whose millings are Dexter, Independent, Schlage, Weiser and Yale. The Independent L1054B key blank is also found under Dominion, Ilco and Rad.

The advantage of using manufacturers is grouping all of the key blanks in one section. Part of the reason is that original equipment key blanks and neuter bow key blanks may not have a number and/or name. This makes it harder for less experienced locksmiths to find the proper key blank.

Using a key blank manufacturer’s numbering system limits key blank number duplication. The most common numbering system to use is the Ilco EZ numbering system. The EZ numbers are used by other key blank manufacturers and many lock manufacturers for their other manufacturers’ lock cylinder options.

For example, JMA USA Quickblanks use the EZ numbering system. They offer more than 100 of the popular key blanks. Quickblanks are available in brass and nickel plate and are sold in different quantities including some numbers available in a jumbo pack.

However, not every key blank manufacturer makes all of the key blanks you will want to stock. Jet Hardware offers their "Silver Line" key blanks that are manufactured from nickel silver, a copper alloy usually composed of nickel and zinc. Nickel silver is harder than brass, providing high strength and corrosion resistance. "Silver Line" key blanks are available for many of the cylinder key blanks. How do you number these key blanks? In addition, some locksmiths include original equipment and neuter bow key blanks along with the aftermarket key blanks.

Another consideration is the cost of an original, restricted, patented or specialty key blanks versus aftermarket key blanks. If your company charges more for original equipment or specialty keys, then having these key blanks on the keyboard may not be a good idea unless employees are trained to know the difference. One locksmith company keeps the original equipment, restricted, patented and neuter bow key blanks in boxes in a different room to ensure that when an employee cuts any of these keys, the customer will be charged the appropriate price.

Once the cylinder key blanks have been populated, then determine the locations for the remaining key blanks. For some locksmiths, the more expensive vehicle remote head keys and fobs are sometimes kept in a locked cabinet or safe.

For service vehicle, a small keyboard and excess metal head key blanks can be stored in drawers or cabinets. Placing molded plastic head transponder key blanks and remote/integrated/fobs in a cabinet or drawer is a good idea. This eliminates the ability of a person looking in and seeing thousands of dollars of key blanks.

The magic of a keyboard is the ability to make changes. Unfortunately, the time it takes to make those changes seems like forever. However, there is no better way to learn your key blank numbers.

For more information, contact your local locksmith distributor or the following manufacturers:

Ilco: www.kaba.com

Keyline: www.keyline-usa.com

Jet Hardware: www.jetkeys.com

JMA USA: www.jmausa.com

Pro-Lok: www.pro-lok.com