Replicating a Secure Telephone Key

Explore the process of reverse engineering and replicating a secure telephone key for the Motorola Sectel 9600 in this 19-minute Hackaday conference talk. Delve into the history of the STU-III secure telephone, originally developed by the NSA, and learn about the challenges of creating compatible keys for these devices. Discover techniques for analyzing and reproducing both mechanical and electrical components, addressing low-volume manufacturing issues, and developing strategies to overcome obstacles. Follow along as the speaker demonstrates the step-by-step process of fabricating a functional key, from initial analysis to final testing. Gain insights into electromechanical assembly, simplifying complex designs, and verifying connections. The talk also touches on firmware analysis, dynamic analysis, and explores potential applications for other Type 4 devices.

Intro
Has this ever happened to you?
STU-III is born!
What about the key?
Keceptacle
DIY keys?
Mechanical reproduction
Electrical reproduction
PKS-703 Key Reader
Verifying connections
A few minutes later...
Electro-mechanical assembly
Simplifying teeth
It fits! But does it work?
Putting it all together
Can we clone this?
Improvised CIK-DIP adapter
So excited!
What if I want a...uniquely designed...t-shirt?
WIP: firmware analysis
WIP: dynamic anlaysis
WIP: misc type 4 devices