by MacGyver101 » 5 Nov 2010 20:01
Hrm. Could be a number of things.
Random guess: if there's a very deep cut in that position on the key, I've seen cases (I'm thinking of one of my Yale KIK cylinders here) where the spring actually normally sits inside the plug... and, if you pick it open in that position, you can trap and damage the spring, which could then interfere with the bottom pin. Have you looked at the pinstack? (i.e., do the spring, driver and bottom pin look normal?)
...or perhaps I misunderstanding your question, and you're describing a situation where you've managed to trap a spooled driver pin?