TOWCH wrote:Heating the lock in an oven or with a propane torch will probably help with removing the non-removable pin. Afer you have done this, there is no garuntee against distortion so that lock is no longer valid as a Proof of Concept lock.
If you drill a straight hole, then you can hammer a slightly tapered square pin into it. If you drill a tapered hole you can hammer a tapered round pin to match and that might also work.
My 321 has what looks like a tap broken off in to it. I'm eventually going to try taper ground piano wire with a screwdriver turned and filed to grab the wire, with a ring to lock the wire in place.
As already mentioned, Wire EDM is supposed to be good for removing broken taps and ez-outs and such, but I think it's too expensive to use on an abloy when they have rekeyable versions for sale?
If you encounter a ball bearing the simples way to solve that problem is to drill a hole from another angle behind it to give it some place to fall out. If you're going to mill out a section, that would be a good spot to drill, or if not, then opposite the milled section so that you don't have to look at the hole.
Personally: I think it's a safe assumption that the ball bearing is roughly the same size as the plug you're trying to remove so assuming that it is halfway inside the plug retainer: then just do the above method and forget about removing the broken grub. Then you can tap your hole and put in a removable grub screw.
(Use a center punch and a smaller drill bit to pilot drill a hole to prevent your hole from wandering and missing it's mark)
Fill any imperfections in the non-removable grub with silver solder or epoxy puddy and file, sand, and polish that side of the lock to blend the non-removable pin if you want.
And it is not expensive to make your own, here is a good starting place:
