Credit Card Sized Wrench Set- the Sunrise Wrench

I'm a big fan of wallet multi-tools. They cram so much useful stuff into a flat piece of metal the size of a credit card; it's amazing. However, cramming everything into one handy little package means that not every tool works as well as it could. I've had a fair amount of trouble using the larger wrenches on each multi-tool I've owned. When you try on use them on a nut or bolt that's in an awkward position (like on a skateboard or bike, for example) instead of in the middle of a flat surface, they just don't work. That (along with my apparent obsession with wrenches) is what inspired me to create this. It has no problem with awkwardly located nuts and bolts and fits nicely inside a wallet.

My current design (the focus of this Instructable) has the following features:

• 1/4" wrench
• 5/16" wrench
• 10mm wrench (can also handle 3/8" nuts and bolts)
• 12mm wrench
• 1/2" wrench
• 1/4" hexagonal hole that can be used to attach the wrench to a keychain or to drive 1/4" screwdriver bits

I'm also working out the kinks of a new design (Image 3) with the following features:

• 4mm wrench
• 5mm wrench
• 3/16" wrench
• 1/4" wrench
• 5/16" wrench
• 10mm wrench (can also handle 3/8" nuts and bolts)
• 12mm wrench
• 1/2" wrench
• 1/4" hexagonal hole that can be used to attach the wrench to a keychain or to drive 1/4" screwdriver bits
• Gear tie
• Bottle opener

- Hacksaw

- Coping saw

- Small files, such as these

- Large file

- Calipers

- Drill or drill press

- Bench vise

- 12 to 14 gauge steel; I would recommend 14 gauge, as it is roughly the thickness of two credit cards

- Download the attached template and print it out. Make sure it is the right size. The template looks different than the one I used since mine was made from a rough sketch.

- Attach the template to some steel (I used glue) and cut it out.

- Use a 1/4" drill bit to drill holes in roughly the locations marked by the black dots in the first image. Take your time and make sure the drill is in the right place.

*I chose to do this before cutting anything out in case I screwed it up somehow.

- The hole made by the 1/4" drill bit is nearly the right size already. You just need to use the small files to add "corners" to the 1/4" hole, making it hexagonal.

- Test it with a 1/4" screwdriver bit to make sure it is the right size, or measure it with the calipers.

- On your template, the body of the wrench is dark grey. We basically want to remove anything that isn't that colour.

- I started by cutting out the general shape of the wrench with the hacksaw.

- I then used the coping saw to cut out the "jaws" of each wrench. The holes you drilled earlier will allow you to pivot the saw blade and make the cuts at the correct angles.

*Note: it is better to cut the jaws too small than too large, as you can always make them bigger later.

- This is the most important (and the most time consuming) step. Start by using the big file to clean up the edges you cut with the hacksaw.

- Next, use the small files to clean up/enlarge the jaws of each wrench. Be sure to stop frequently and measure them.

- Once the jaws are the correct size, file all edges smooth and proceed to the next step.

- Remove the template from the wrench. I used a wire wheel to get rid of all the paper and glue.

- I chose to leave the metal bare and give it a protective coating of clear spray paint. However, what you do is up to you! I think it'd look pretty cool in different colours, or after being highly polished.