Balance rail pins, key buttons

[Newton Hunt]

I haven't done this yet, but...

X-acto makes several widths of chisel point blades.

Take an aluminum or brass rod 3/8" by 4" and mill, cut, file chew two
flats parallel to each other with a width that two chosen blades with
bevel inside equals the desired width of the mortise.

Secure these blades to the rod with CA, low temp solder, screws,
baling wire or chewing gum so the center line of the blades is
parallel to the axis of the rod.  To help prevent flexing of the
blades they should be supported close enough to the cutting edges as
possible far enough away to allow proper functioning.

Secure in a drill press and change the drive belt to the slowest speed
to prevent easy rotation.

An appropriate pin secured near the end, centered to the width, in a
longish board with longitudinal parallel lines drawn at the opposite
end clamped to the drill press table so the hole positions the key
under the chisels, which are carefully aligned parallel to the lines
at the other end of the board.  Placing the key on the pin, aligning
the front of the key parallel to the lines, lower the chisels to
remove excess glue, size, move slightly to center, and unbush the
center mortises.

In the case of the very narrow mortises the ends will need to be
drilled open to help prevent splitting and allow easy chip removal.

		Newton