I was finally able to drive my RX-7 GSL from Denmark to Italy a few weeks ago. Now she's patiently waiting in a garage until the paperwork is done.
I'm not so patient but the notorious Italian red tape is certainly not getting any faster during Covid times.
The 2nd key of the RX-7 is not looking good, and I don't want to end up with one key only. RX-7 key blanks seem to be available for 1983-1985 versions only, online (maybe I'm wrong), but I did what I always do in these cases - drawing board.
So I started scanning my key:



and I reversed engineered it. A caliper helped too.
This is what I got after 3D printing it with a HP MJF



Super cool IMO. The key is weak but very precise and I was able to test, with the utmost care, that it is indeed able to turn the key fob like it should!
So - proof of concept passed!

Back to the drawing board:


This time, I will 3D print the key blank, as well as my Mazda's proper final key, in 3D printed aluminium, and the Wankel rotor in plastic.
I've never tried 3D aluminium printing service, but on paper the result should be strong enough to be used daily.
The two parts will be bonded with 2 components epoxy resin. I should end up with a finished key, and a key blank, with a Wankel 'head'.
I will have the parts in about one month and will let you know how it goes.

 

Have you checked Rotary13b1.com?

Key Blanks: Rotary13B1.com

 

nicely designed solution! lets see the final product plse
...and best of luck with the Italians. I own a vintage Ducati. Been there...

Stu A
80GS
AZ, USA

 

Nice work.

https://www.mazdatrix.com/product/ke...-rotor-type-b/

 

Looks cool but I would make the rotor in aluminum as well, or like linked above buy one that's already made.

 

Very nice work!!!

 

Thank you for the information and support.
Had I noticed those sites earlier, I may not have started the design... but it wouldn't have been so much fun and I wouldn't have learned a few things.
Trying the first aluminium key is going to be thrilling.

 

very neat, feel free to shoot me a PM if you need part numbers and availabilities
i sit in front of Mazda USA's dealer web site all day

 

Final result.
3D rotor printed on HP JetFusion, aluminium 3D printed key, brushed
Works nicely.

 

Very nice!
How did you do the 3D scan?

 

The 3D scan was made with a Laser scan owned by the designer that works for my company (we make slot cars in 1/32 scale - such as the Mazda 787B)
However, after studying the 3D and the shape of the key, I realized that these keys are much easier to duplicate than I thought. A caliper and some knowledge would suffice.
Basically, the shape of the basic cut made in the blank is standard, the dept can be single or double, and the spacing is always the same.

 

That looks great!! Looks like the parts fit together very nicely as well!