"I've made a huge mistake"

[YouLuckyFox]

I made a rookie move while I was repinning an ABUS 83/45-200 (I like this for security pin practice because the tolerances are really tight, but the keyway isn't.) I was planning on practicing with a couple of combos being that I have the day off . Unfortunately, this happened:


Here's a picture that might help me explain what happened:

That pin you see in the image above had become lodged in one of the pin chambers! Totally a rookie move, I was too careful by half when trying not to let the bible unload the 5th driver chamber into the 6th key chamber of the plug. I was pretty depressed and was not able to get that pin back into the plug by rapping or using a small safety pin to push it back in. I was able to recover the lock, though. Here's how:
I bent the ends of two safety pins like such with a pair of needle nosed pliers:



Notice that the back of the retaining pin chamber is exposed, hard to see but from the subsequent pictures you should be able to figure out the area I'm referring to:


I was able to work as many as two coils out of the small opening using the safety pins like so:

From there I was able to use the hook-ended safety-pin to yank a coil free from the chamber:

Using a pair of needle-nosed pliers, I was able to grab the end of the spring and remove the entire spring:

From there, I let gravity allow the pin to fall back into the plug and my lock is now able to repin, only disadvantage is that the plug can now overturn. I'm okay with that, but will have two new locks of the same make on the way soon. I noticed that something like a collet is used to keep the pin in there. If I felt like it, I could use a threaded steel with the correct taper and yank the collet out (yeah right, I know; but maybe! ) and replace spring and pin and re-secure the collet. But a new padlock of this sort is only $30 maximum. Hope this is of use to someone! If I could've done something better, please tell me. I welcome any constructive criticism.

Sorry for any lack of quality in the pictures!

[GWiens2001]

Lack of quality in the pictures??? Wish I could get macro shots like those!

I like your solution to the problem. Is there any reason you can't just replace the spring and reassemble?

Gordon

[YouLuckyFox]

Hey Gordon! Here's a video showing the predicament:


Looks like if I were able to use a small screwdriver with enough force to remove that collet/bushing (terminology?) around the pin, should be able to do it. Unfortunately, giving the pin itself a good tug just scratched the brass up. Seems like it's really in there. Thought of freezing the plug first to shrink the parts, but that might not be viable. It is really stuck in there, I've fitted pins in tight tolerances using a hydraulic press before, figured that's probably how this collet/bushing was put in there in assembly. I imagine it'll be an extremely snug fit, think I should give it a try anyway? It's the only thing keeping me from reassembling the plug . All ideas are welcome!

[GWiens2001]

Perhaps you can open a vice just a little wider than that collar, then use a brass drift punch (buy a solid brass rod at a hardware store for 3 bucks), cut it down to about two or three inches, and try using a small hammer to lightly tap the collar out from the inside of the plug.

Or put a socket whose opening is slightly larger than the collar, use the same brass rod cut to about 1 inch, then close them in a vice, using the vice to press the brass rod against the collar from the inside, and thereby pressing the collar out of the plug and into the socket. That is what I would try.

Good luck with it.

Gordon

[YouLuckyFox]

Thanks for the advice! I'll have to give it the old college try when I can. I'll post updates in this thread.

[YouLuckyFox]

Got some bad news. I was yet again too clever by half. I thought I would use a flat head screwdriver (thought I'd make due without having to buy a drifting punch or use any tools at work) and rest the outport of the collar in the gap of a vice, resting the plug on the jaws. After three pretty moderate taps (not swings)...well, see for yourself:


Must be something about brass, it doesn't behave like other metals. I've noticed brass and aluminum have some very unique qualities when it comes to fabrication.
I coincidentally made the exact same mistake (as in, having the retaining pin go in a pin chamber) with another ABUS 83 plug, so I think I better use the right tools (pin or drift punch) next time.

RIP collar and pin Sorry for background noise in video, that microphone is so sensitive it makes my breathing and the crows outside sound a lot more amplified than it really sounded, I'd play Tapps in the background if I could redo the video.

[YouLuckyFox]

Bytheway, plug still operates, so no "real" damage done .

[GWiens2001]

YLF,

At least you tried. Now you can try your next project with this lock... Making another collar and spring. Take the plug with you to the hardware store (I'd recommend ACE hardware), and get a solid brass rod about the width of the collar. Put it on a drill, and use a file to machine the narrow 'pin' tip. Cut it off, flip it around, and drill a tiny hole for a spring. Then reassemble!

Sorry, I love projects like this. I get caught up in finding solutions.

Gordon

[YouLuckyFox]

Great idea, Gordon! Thanks for giving me hope . I like being able to fix things. I could take it to work and have a fellow worker machine it to the right diameter in a couple seconds, but I think I'll do it by hand. I've grown fond of doing things on my own. I'll be sure to get surplus material so I can allow a few more mistakes to be made .