Description

I’ve wanted a Lexus key card for my 2005 GS 300 S19 for ages, but they’re basically impossible to find in Europe. So I made one myself. I used the internals from an aftermarket smart key I already had. After looking around online, I found most Toyota and Lexus aftermarket keys from AliExpress/eBay come from Lonsdor and belong to the LT20 series. My smart key is an LT20-01, and the files I’m uploading are laid out for that board shape specifically. But it could easily be modified to fit other LT20 boards or other boards with a similar layout/shape. Using an original key might work, but depending on the model they may have a different layout and would need a different design. To get the board as thin as possible, I removed the buttons and the battery holder. I also desoldered the RFID module and reconnected it with very short, fine wires, to make it sit next to the board. For the battery I used a CR2032 with cables, which I soldered to the board. I designed the case for the thin original emergency key just like the original, but had to make a second version, as the locks on my 2005 GS only accept double-sided keys. I think Lexus used one-sided keys from 2007 onwards. The second version keeps the standard double-sided TOY40? keyblade inside the case, which I removed from its housing by pushing out the pin in the handle. To make it perfectly fit in my Lockcard Wallet, I mostly stuck to standard credit card measurements (85 × 53.8 mm), but also made a version with the smaller size of the original (79 × 53 mm). It is 4.7 mm thick in total, so roughly 1.6 mm thicker than the original. I secured the electronics as well as the lid with thin double-sided tape. The lid can be removed carefully with a fingernail. I suggest printing at >50% infill with a 0.1 mm first layer. Depending on your printer’s accuracy, you may need to tweak your slicer a bit to make the clips fit. My final prints were done on a Bambu Lab H2D with PETG-CF. There are 4 models in total: LexusKeyCard: Origi