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i think i always went half a gauge under but try copying a 5 gauge on a normal 5.5 gauge tell your customer when they comment it doesnt look the same that you only cut them on this blank because they last longer and the curved ones break,

 

i also sometimes scoured a slope on the tops to cater for the slope on the top of their key

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Thanks discodave but all I want is to be able to buy a blank that will match what the customer brings in. I don't want to try half a guage under, I don't want to tell my customer it doesn't look the same because they won't believe me! And I don't wan't to scour slopes because it will look crap. All I want is a key that matches the customers key. Surley thats not too much to ask

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