Masking of keyways when anodizing & electroplating

A. Hi Jim. Keyway sizes are standardized according to the hole diameter so I see no essential reason pull plugs with built-in key plugs are not available for plating; they are available for powder coating. I would suggest talking to your pull plug supplier about why they are not available -- maybe they just haven't heard of the need but will be able to accommodate it.

Luck & Regards,

A. Hi Jim!
Though I haven't used this on keyways specifically, I have had great results on internal bores with other types of contour.
Find a catalyzed silicone mold material that has some compressibility.
Make a few "parts" out of acetal rod, with a good smooth finish, with 2 details:
- they must be oversized in every dimension by about the compressibility of the silicone
- elongate the mold "parts" longer than your actual parts, and with a narrower diameter "tail" on each end which you can pull as you're slipping the parts over them, which should make them shrink in diameter and when you release the tails, they'll seat in the parts. I use a 3-part mold with tight slip fit mating surfaces at the joining ends, so silicone doesn't leak everywhere. Be sure not to introduce any bubbles!
This may take a couple tries, but when you hit the sweet spot of no leaks, it ends up saving time and reworks, and is a faster turnaround than having a custom plug professionally made.