I can certainly see why someone making a key remotely using the key code wouldn't guarantee success. Volvo dealers used a die key punch for the 140/240, 700/900 keys based on the key code. The original key code (and radio code) are registered with the VIN. There were two different blanks, a main key for all locks and a valet key for just the doors and ignition, both have the same cut teeth, just different grooves so you can grind a new key using either one. The dies in the dealer key punch kits were known to wear, so you often had to heavily burnish the keys to work properly. Both when grinding or punching a two-sided key, when the key is flipped over it needs to be carefully mounted to align properly. For the last keys I had punched at a Volvo dealer many years ago using the key code, even after burnishing they went through at least five blanks until one of them worked smoothly without having to wiggle and jiggle it. A neighbourhood locksmith could have made a better copy on an aftermarket blank than the worn out dealer punch.
--
Dave -still with 940's, prev 740/240/140/120 You'd think I'd have learned by now