New generation Abloy Protec cutaway

[SnowyBoy]

lol at you lot having rows on my thread xD

[ridderhenck]

It,s not hard at all to get the discs out,there is a small inbusscrew on the side of the padlock,once you,ve removed this small screw,there will be no problem whatsoever to remove the discstack

[Baloopaloop]

Ah, I wondered about that, I'm thinking that an abloy would make a fairly easy cutaway, correct me if I'm wrong but I'm thinking that as soon as I get access to that milling machine it should be something to try right away

[ridderhenck]

You,re a 100% right,I,ll send you some pic,s if you like

[Baloopaloop]

Send away

[Baloopaloop]

Hey peoples, in that case, does anyone know a good place to get a reasonably priced pair of abloys? Cause sooner or later I'm going to take a shot at this

[SnowyBoy]

Hey peoples, in that case, does anyone know a good place to get a reasonably priced pair of abloys? Cause sooner or later I'm going to take a shot at this

It's not as easy as it looks, trust me. You need to have the right cutters and know the exact measurements to allow all to be seen without the side bar falling out.

You seem a little too confident, and that's when mistakes (and injuries) will arise. Just take your time.

[Baloopaloop]

yeah I didn't figure it would be as easy as it looks but then again it seems like you can make the whole cutaway with one big cut where some locks require tons of little cuts. How do you measure all the inner cavities of the lock without cutting one directly in half? it seems like it would take a great deal of thinking anything I should think about while I make the cuts if I get one?

[mh]

How do you measure all the inner cavities of the lock without cutting one directly in half? it seems like it would take a great deal of thinking

Indeed it does require some thinking But it can be done at the first attempt, just remove he plug and you can take all the measurements...

Cheers,
mh

[Baloopaloop]

but how to you measure into the ball bearing cavities and such?

[SnowyBoy]

but how to you measure into the ball bearing cavities and such?

I've got cutting these down to a fine art now (if i say so myself). I've done that many of them that it can be done by eye and using the markings on the padlock themselves.

Invest in a micrometer, the depth gauge is very useful. But again, with the Abloys, they have a spring on the back of the barrel which needs to still act, so the depth you thought you could get away with will be wrong.

As for the cuts, I use a combination of a 3mm and 6mm bit. The main window is done with the 6mm and takes about 2 hours since there is 4 sweeps for every rotation. If you use say a 12mm bit, then the window will have seriously rounded edges in the corners and IMO looks like no effort has been put in.

You can measure where to cut central to the BB pathway by using the disc on the side to line the attachment up.

p.s Protecs & disclocks are different cuts to the classic and profile by about 4mm on the main window.... so make sure you measure every job before cutting.

[Baloopaloop]

thanks for all the info so the spring is behind the disk stack?

[SnowyBoy]

thanks for all the info so the spring is behind the disk stack?

Yeah, the disc barrel has a hole in the back of it for the spring to sit in half way. It's to allow smooth operation when the stack retaining ring is done up tight instead of it being real stiff (i tried without).