This is a pill case made from a lug nut, a matching threaded bolt, and an O-ring. I sell a commercial version with a custom threaded aluminum closure in my Etsy shop. If you want to make your own like this prototype version, you'll need a chromed 1/2-20 lug nut, a matching 1/2-20 stainless steel bolt, a galvanized D-ring (5/8" across, 7/16" tall, 0.080" wire diameter, e.g. Serv-a-lite D-7) and a black rubber O-ring (7/16" ID, 9/16" OD, 1/16" thick). 3/4" is probably the shortest bolt you'll be able to find, so you'll have to cut one down to about 3/8" including the cap. A hacksaw is best for this operation as high-speed cutoff wheels tend to mar the threads. It's hard to make a clean cut without mounting the bolt in a bench vise. Be sure to use a drop of oil to lubricate the blade. After cutting, the thread can be cleared by running the cut-off bolt through a 1/2x20 die (or a 1/2x20 bolt if you don't have a die).
To attach the D-ring, you need to drill a 5/32" transverse hole through two opposing flats on the bolt cap. I recommend a step-drilling process, performed on a drill press equipped with a vise, beginning with a 1/16" bit and proceeding in three steps up to 5/32". The galvanized steel D-ring is then opened (insert the blades of a scissors into the ring and pull the handles apart to do this) and set in the bored hole by compressing it between the jaws of a bench vise.
Clean all the parts with detergent and water and dry them in a warm oven. Then slip the O-ring down around the threads of the cap, thread the cap into the lug nut, and mount it on your key-chain. Done!
last modified 2009-12-07