milled cutaway pin tumbler issues

[unjust]

so with only a few folks at the shop last night for open locksport night, we decided to use the bridgeport mill to make a few cutaways. (pics coming)

after milling off enough of the side of the bible to see where the pin stacks landed and discovering that we didn't have an endmill in the 1mm range (muchless the speed on the mill to appropriately drive one in brass) we got creative and used an abrasive wheel to cut the slots exposing the shear line and the pin stacks. this produced burrs within the bible, which careful filing, sanding and application of a dental pick were able to remove, but driver pins 1 and 5 are still resisting movement enough to make the lock not a good demo piece.

my suspicion is that there's still burr or that the edge of the slot in the stack rolled in slightly, but i'm at a loss on how to clean that up. anyone have any brilliant ideas, or come across similar situations using more typical tools like a dremel?

[gloves]

my suspicion is that there's still burr or that the edge of the slot in the stack rolled in slightly, but i'm at a loss on how to clean that up. anyone have any brilliant ideas, or come across similar situations using more typical tools like a dremel?

Yay for pics coming

You may use a Riffler file to reach weird spots or keep trying by hand with abrasive paper. Last solution which comes in my mind would be to isolate open the part, cover everything else in tape or wax and put in either concentrated HCl or sulfuric acid to dissolve the pesky burr. I also considered anodizing (again with only the burr to be removed isolated) in a sodium chloride solution (so that chlorine reacts with it) though I tried this only on ferrous metals.

Awaiting pics, they'll help too.

Cheers

[Violaetor]

Not seeing your setup I can only speculate, being that it is pins 1 and 5 that the bible may have compressed and the cylinders are now slightly misshapen 'pinching' those pins.

[mcsteve]

That was fun, wasn't it? I'm thinking maybe a thin roll of emery cloth run through the pin chambers a few times.

[unjust]

Violaetor i suspect you've hit the nail on the head. it's difficult to see because portions of the bible have been removed, but odds are that at least one chamber deformed the bible in manufacturing, or may have been crushed in the milling, although i don't recall clamping in that orientation at any point. i think i'll be trying to make some sort of taper to shove in.

mcsteve, it was, and i was able to get some crocus cloth in, but not rolled, as i didn't open the top of the chambers. remind me to show you the progress on the sfic decoder on wednesday.