Recently did this write up for the Caprice board where all we have are fixed keys from the factory. Then saw that you guys also have some of the fixed keys as well. If you want to convert them over to a flip key it is possible as long as you have a good bench grinder. No programming or key cutting needed.
I bought some aftermarket flip key cases from China a few months back ($12.00 each off Ebay, multiple sellers) but never got around to doing the conversion since I figured I would need the assistance of a locksmith to cut the new key. Since I broke my fixed key any way figured I would tear into it and see what could be done. Turned out very nice.
So first I confirmed with the key unlock buttons detached from the key you can still start the car. Which means there is a transponder chip somewhere in the head of the key assembly. I could really only see one area that was thick enough to house it. I scratched a bit at the surface of it thinking the chip would be housed in some silicone or something but all I felt was hard plastic. So started ripping and tearing at the plastic to see what I could remove. Not much is the answer. So I moved to a bench grinder to thin out the plastic walls a bit.
So once the chip was loose I then inserted it into the head of the new flip key case. It goes in the top section where the key pivots. You remove the small Phillips head screw at the back to separate the key pivot section of the case. Then you will see the spot for the chip. Pops right in.
Then I turned my attention to the key shaft. Still had a lot of plastic attached to it after I broke it out of the case. Turned to the bench grinder again to remove the plastic attached to the metal shaft.
Once it was all clear of black plastic I could see the shaft was very similar to the key blank that came with the new case. All except for a pin slot at the top of the key shaft that is used to hold the key in the base by inserting a metal pin to wedge it into the base.
So lining up the shoulders of the new and old key shafts I could see the slot runs right through the middle of the hole that is present on the original key. SO I used a dremmel cut off wheel and made a slot right through the middle of the hole. Went a little too deep on mine so be careful those things cut fast.
Getting the key shaft back into the base was a bit difficult. Seems the factory key is a bit thicker and wider at the top than the China clone. Not much, but enough to cause an issue. Little fineness on the grinder made it slide in. Re secured the pin into the base to lock the shaft in place and it formed a solid unit.
Reassembled the case ( I may need to do a video on how to do that it's a bit involved ) and put a Holden sticker on the back and it is good to go. The case came with a Pontiac and Bow Tie Sticker but I got the Holden ones from the "Badge Man" Gary Whitby. I swapped over my internal circuit board and fresh battery into the new case but you can just transfer over your original buttons and battery if you prefer. They should fit just like factory.
On Ebay a good search term for the item is "3+Panic Key Fob Case caprice"
From what I hear you can get replacement chips and program them to the car. Might be a better option than grinding the old one out? Anyone looked into those?
EDIT: Found out some more info on the Chips: The chips are Philips 2nd Generation Crypto chips. You can get them individually. I see one on ebay now for about $9.00. The Philips Crypto 2nd generation transponder chip is also known as the 46 chip or the Philips Crypto. All the ads I see says you have to take them to the dealer for programming but many of the G8 guys have been programming it themselves successfully using the instructions in the owners manual . Basically you have to have a good working key to do it. Turn the car on with your good key, turn it off and within 5 seconds put in the new programmed key and turn to the run position. Done. May want to buy one in case the grinding gets out of hand! LOL