Brass padlock cutaway advice

[Baloopaloop]

Hey peoples, I'm making a few brass cutaways and I was wondering if there is any advice on grinding down to the pin chambers that I should know. I made one yesterday and a big sheet flaked off and too the spokes inbetween the pin chambers with it so all the pins come out, what did I do wrong? Any info or advice would he helpful.
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[adrenalynn]

The plug should be fully disassembled before you start working on it. What are you using to cut it down? Generally the plug should probably be hand-filed.

[Baloopaloop]

Well I'm using a dremel and grinding bits in a drill press, I do fully dissasemble the lock before I start working on it, even the shackle is removed.

[SnowyBoy]

You'll never get a clean cut without the right tools, trust me.

[Baloopaloop]

what could I try though, I can't afford any machines right now so.... what would you say is the best way to go about doing it with the stuff I have?

[SnowyBoy]

what could I try though, I can't afford any machines right now so.... what would you say is the best way to go about doing it with the stuff I have?

There's two options (comming from someone who has experienced the process).

1) Hacksaws, files, & dremel (also a lot of swearing & injuries) = functional yet extremely scruffy cutaway with at least an 90% failure rate if it's your first.

2) Patience = you finally get a machine and wondered why you bothered wasting time making cutaways by hand.

It took me a year since taking locksport up to get a machine, and since I have I've not looked back.

Anyway, if you want me to hook you up with a fairly priced cutaway I have two types right now for sale.... one of which is under £20 (don't let the price fool you, my cutaways are, dare I say, extremely high quality and better than any of the tat you've probably seen on Ebay.

http://img19.imageshack.us/img19/8533/cimg5851.jpg

If you're interested, drop me a PM & we'll sort something out.

p.s Wear goggles when using dremels with their own supplied cut off wheels, grinders, and routers because they are rubbish quality and prone to shattering.

[tballard]

p.s Wear goggles when using dremels with their own supplied cut off wheels, grinders, and routers because they are rubbish quality and prone to shattering.

No, wear goggles ALWAYS when the tool is on. Bits can shatter or parts you are cutting can fly. Usually this happens when you least expect it, and they tend to aim squarely at your eyes. Safety glasses or goggles start at under 5 bucks, and there is no excuse not to use them. If you are doing a lot of cutting/grinding, it is also a really good idea to wear at least a dust mask. Small metal particles + lungs = bad.

[adrenalynn]

OT, I know, but I hang glasses and, for some tools, glasses + face shield from some critical part of the equipment. I have an independant set for every spinning tool like that. Without taking the glasses off the tool, I can't operate it. As long as they're in my hand, I might as well put 'em on.

No excuses that way, and I'm big on the "it's only one cut" excuse generation. Having metal shards picked out of my eye in the middle of the night at an ER convinced me to break the habit...

[unlisted]

Plus metal in the eye, then going for a MRI is really a horrible thing...

[edit- thanks squelchtone!]

[tballard]

Just to amplify the already good advice about eye protection, remember that the little shards are also very hot. When I'm working I often have music going via my iPhone, a dock, and external speakers. I used to keep the phone a good 6-8 feet away from where I'm working just to avoid dust problems. I now keep it a good bit further and with the screen turned away from me since a while back I noticed little "specks" on the screen. The little bits of metal dust had not only made it far enough to land on the screen, but retained enough heat to melt their way into the plastic screen cover. (Glad I had one of those on)

[Baloopaloop]

so you who seem very knowlagable about machines for making cutaways, what kind of machine and how much? I'm thinking future investment because I'm not employed right now other than a full time student so I don't have a huge income

[SnowyBoy]

so you who seem very knowlagable about machines for making cutaways, what kind of machine and how much? I'm thinking future investment because I'm not employed right now other than a full time student so I don't have a huge income

I own an Axminster Sieg X2 mini mill @ circa £400

[Baloopaloop]

great, but I'm probably not going to buy a milling machine from the uk so, anyone know where I could get one around minnesota? and snowboy, could I get some pictures of the machine and what the bits look like, or how you use it, I have to figure out if a drill press with a grinding bit would pass for a milling machine if it had to cause my dad already has one of those

[SnowyBoy]

great, but I'm probably not going to buy a milling machine from the uk so, anyone know where I could get one around minnesota? and snowboy, could I get some pictures of the machine and what the bits look like, or how you use it, I have to figure out if a drill press with a grinding bit would pass for a milling machine if it had to cause my dad already has one of those

A drill press would work with say a cross slide vice, but to be honest, nothing is accurate and solid feeling as the sliding tables.

I'll try and get a video of me cutting tomorrow. I got to clean the camera memory out first.

[tballard]

A drill press will work, but the bearings are not designed to take the sideways force, and you can screw up the quill pretty easily if you get overly aggressive.