Plug stuck in Shell

[szekely]

Howdy everyone. I am having problems trying to get a plug out of a shell. It's from a master #1 that I took apart and picked. It is free to rotate in the shell but when I push on it from the back it won't budge. I did the same procedure yesterday on a master #3 and it just slid right out. Since it's from a padlock I'm pretty use theres no clip thing I have to remove and I didn't yesterday. I have already searched through these forums and googled the problem but there was no solution I could find. All suggestions would be helpful.

[Oaklandishh]

they bend in the back of the plug a little bit so turn it pi/2 radians and push really hard. if it still doesn't come out put the outer shell resting on a clamp and hit the back with a hammer.

[Oaklandishh]

I meant vise, not clamp. I even made you a diagram.
http://i14.photobucket.com/albums/a348/ ... ERplug.jpg

[szekely]

Turning it farther didn't work so I ended up using the hammer idea. First few hits didn't do anything but then it loosened up and I got it out. I think my shell cracked when I was prying off the part of the padlock that kept the shell in place. I had to use a hammer and screwdriver which might have damaged the shell. Thanks you for the advice

[szekely]

Well now when I'm trying to put the plug back into the shell it won't fit theres marks on the sides and rim of the shell opening which I attempted to bend back. Have any idea how to make the shell and plug fit together again?

[MacGyver101]

I think, in order for people to help from here, a photo would help a lot.

[0x41414141]

Usually, the problem happens if you over tighten the screw that holds the plug. At least, from my experience.

(I do know that it wont solve your problem, but if it helps anyone, it is worth it)

[MacGyver101]

Usually, the problem happens if you over tighten the screw that holds the plug.

I think that you're thinking of some Key-in-Knob cylinders (like a Schlage) which use a threaded nut to hold the plug in place, instead of a circlip? If so, I don't think I've seen a Master Lock padlock that uses those?

(Just didn't want szekely to think that he'd missed taking a screw out somewhere!)

[Legion303]

they bend in the back of the plug a little bit so turn it pi/2 radians and push really hard.

You are the wind beneath my wings.

-steve

[0x41414141]

I think that you're thinking of some Key-in-Knob cylinders (like a Schlage) which use a threaded nut to hold the plug in place, instead of a circlip? If so, I don't think I've seen a Master Lock padlock that uses those

Good catch. My bad.

[Raymond]

Master padlock plugs are held in by bending one part of the shell into the groove in the plug. The plug will come out and go back in if the plug is rotated so the bottom of the keyway is inline with the bent part. The bottom of the keyway is flatter than the rest.

If you have boogered up the plug and shell, and scratched it, you will just have to smooth everything out ahain before it will fit.