Method for making a key for driving tamper-proof bolt

A method of constructing a key for driving tamper-proof bolts, the key including a tubular sleeve having a transverse aperture at a first end thereof and an outer surface, a plunger rod axially slidable within said tubular sleeve, said plunger rod having a camming surface at a first end thereof and having a longitudinal axis, and ball means captively held by said tubular sleeve adjacent the transverse aperture, said ball means being cammed into the aperture in said tubular sleeve by the camming surface upon axial movement of said plunger rod, said method comprising the steps of:

• a. molding a plunger handle onto a second end of said plunger rod opposite the first end, said plunger handle molding step including the steps of providing a flattened surface parallel to the longitudinal axis of said plunger rod and providing a flange adjacent an edge of the flattened surface nearest the first end of said plunger rod, the flange projecting away from said plunger rod beyond the flattened surface;
• b. molding a key handle onto a second end of said tubular sleeve opposite the first end, said key handle molding step including the step of forming a chamber within said key handle for providing access to the second end of said tubular sleeve;
• c. inserting the first end of said plunger rod through the chamber of said key handle and into the second end of said tubular sleeve until the flattened surface of said plunger handle has entered the chamber in said key handle;
• and
• d. inserting a pin transversely through the chamber of said key handle parallel with and adjacent to the flattened surface of said plunger handle for preventing said plunger handle from rotating within the chamber of said key handle and for retaining the flange of said plunger handle within the chamber of said key handle.