Am I boned?

[Thorvindr]

You the switch is actually approximately in the middle. You don't want to notch it all the way to the bottom because the tension from the switch helps hold the key in.

One of is is misunderstanding the other. By "bottom" I mean the end that goes into the hole, not the end that sticks out. I cut a notch in the open end (like the one inyour photo but WAAAAAAY shallower) and now it works as a twist key. Also: your charge port and kill key don't look loke my charge port and kill key so maybe they're subtley different.

[jbkuma]

The charge port is epoxied into the pommel cap, but it's the standard switch craft port. There's probably some slight variation between ports as to how deep and the exact location, although it should be fairly standard a slight variation at these scales can seem like a lot.

The key is a 6-32 thumb screw glued into a piece of a mechanical pencil.

[Thorvindr]

The key is a 6-32 thumb screw glued into a piece of a mechanical pencil.

Oh! Clever! Cool pommel, too. You make that yourself?

[jbkuma]

Thanks! The brass outside is 17ga tubing, the black part is a 3D print, the brass insert is a sew-in snap. The charge port happened to fit in perfectly.