The inside cover was swaged onto the lock body so I popped the hinge pins and took the door with me to my workshop. I carfully ground the brads off just enough to pop the cover. The key tip was broken off and still in the lock. It sheared off just behind the end of the counter drilled barrel hole.
I dug around in my junk box and found a brass blank that was very close. I measure it all out and almost grabbed my Dremel to make the initial cuts but since I only had one blank, I used a hand file. Five minutes later it fit and worked like an original. I re-attached the cover using countersunk black oxide screws in the corners away from the mechanisms and returned the door, put the hinge pins back in and let the customer try it out.
They asked me to screw the key to the inside of the door so it wouldnt get lost. They paid in cash and thanked me profusely. The most enjoyable lock job I have had in quite a while.
