Padlock cutaway: how not to make. i think i need some advise

[جا&am]

hi all,

i just finished my first cutaway of a abus 65 40 padlock. i kind of new to this cutaway stuff (actually i bought the dremel yesterday). the result is absolutely scrap!! i'm sure it's the ugliest thing you've ever seen! ok here goes the picture but i just wanted to warn you before you die of laughing.

...



...


Ok now the explanations and questions:

1st: as you see, i drilled the pins out from the top. but then i couldn't find a (good and clean) way to cap the holes again. what should i use and how to do it (because the springs always push things out)???

2nd: when i cut the holes, i cut the plug too. this is bad because when i turn the plug to unlock, pins will get stucked.

3rd: i think i did something wrong when i cut the holes... now the pins do not react the same as before. there is a friction point near the plug.. how should i cut to prevent that from happening?

Well i search the whole night for post about making cutaways. i found some pics of cutaways, the 'drilling pins out' stuff and the 'cooking padlock' trick that i will not try. wouldn' it be a nice idea to create a tutorial for this?

[helix]

THAT POOR ABUS, AAAAaAaaAhHHhHhHhHhh!!!!!!!

*Cries into hands*

If I were you, I'd get a little practice with your new Dremel making
a cutaway CYLINDER and make a cutaway padlock later.

* Get a cylinder and take the plug out. (yes, springs and pins out too).

* Using the plug as a guage, mark where the pin cavities are.

* Using a cutting disc, cut lines along the marks you made.

* I personally like to go a little further than the shearline.

* Make sure you clean up any edge that has been cut.

* Make sure the plug fits in and out and turns good.

* Make sure the pins drop in and out of it easy.

* Put it all together.

[Mad Mick]

Oh Boy!

Don't use it on the shed.

[sl_aus]

OUCH!!
That's very similar to my first attempt on a padlock cutaway.

Below is my second attempt.



I used a hacksaw for the majority of the cuts which are visible then turned the plug so no pins were exposed.

The dremel with a cutting disc came next, that was the tedious part - very slowly taking a fraction away.

I didn't remove any pins as like you I had nothing to recap the holes with.

Not the prettiest cutaway around but it serves it purpose.

[DaemonLee]

In the first picture, caught my attention was staring back at me...



Is that a fishing lure?

[illusion]

What!!?!?!?

This just gets weirder... tell me - this padlock wouldn't have a tendancy to jump up and do a backflip on your table by it's own accord?
cos I sure am prepared to believe it at the moment

[DaemonLee]

I'm going to try to do a zone blowup on it, but I'm really curious if that item came with the lock or was added in the process of the cutaway.

[Chrispy]

Keep trying jp, next one will be a bit better.

[DaemonLee]

Keep trying jp, next one will be a bit better.

And hopefully, without fishing bait.

[جا&am]

hehe thank you guys for the advice! nice picture sl... i'm going to try this way.

and no, there is no fishing bait in my padlock. it is lead and a copper wire (the only thing i had to fill the holes after the screw attempt failed). i must admit that i'm as good with the soldering iron (not sure how it's called in english) as with the dremel .

... what a shame! ...

[skold]

it looked good apart from the bombsite of lead...LOL.

I made a cutaway once..it looked good.

[Chrispy]

This is mine. It was featured in a thread a while back. Same padlock.

[skold]

On the subject of abusness.

http://img.photobucket.com/albums/v329/ ... 0_0169.jpg
http://img.photobucket.com/albums/v329/ ... e01a64.jpg
http://img.photobucket.com/albums/v329/ ... 0_0168.jpg

[Fah_Cue]

thats really nice skold

[skold]

for a hacksaw job lol


my new one is being built as we speak