Non destructive disassembly ABUS 78/50

[Nitrous]

Hi guys,

Has anyone successfully opened AND closed an ABUS dual padlock and can share their method? The body of the one I have (opened with a lathe - so, clearly a destructive method) is aluminum and has a rolled edge that holds the back in place. It appears to be black anodized.

I want to disassemble the lock, make some changes then seal it back up.
I've thought about trying something like you'd use to put a tire on a rim. The other thought was to use something like a pair of vice grips with hemispheric jaws to lift up the rounded edge.

The back is formed, so can't be "sprung" out by lifting only part of the edge.

Any thoughts or experience would be welcomed.

Thanks
Nitrous

[GWiens2001]

What is your definition of 'dual padlock'? The Abus 78/50 looks like a standard, cheap combination padlock, so want to be sure we are talking the same thing before I risk giving an answer that is inaccurate. Any pictures if it is not the standard combination lock? Here is a picture of the Abus 78/50 padlock that I found online...



Credit for the picture goes to the site which is hosting the picture www.thanettoolsupplies.co.uk . If it is better to have the above picture as a link for copyright purposes, please adjust it accordingly.

Gordon

[Nitrous]

That is it. I meant "dial" not dual.
Sorry about that

[Nitrous]

This is the 78/50KC (key control) but looks similar to the plain back without the key cylinder visible.

http://www.uk-locks.co.uk/contents/medi ... 0black.jpg

(Frm UK-locks.co.uk)

[GWiens2001]

They could not even be bothered to use a pin tumbler lock on the back? Just a cheap wafer tumbler lock?

Gordon

[Nitrous]

I don't think these are designed for much more than high school locker security.
But aside from that, I'm wondering if an approach might be to make an expanding mandrel to "push" the rolled edge off the circumference of the back plate.

To re seal the back, I think a tool with a bear at the end might allow the rim to be rolled back.
It appears to be aluminum so I would hope that I could use that to my advantage.

Thoughts?

Nitrous

[Nitrous]

Any ideas of "best methods" to accomplish this?

[GWiens2001]

Can't think of any method that would be non-destructive.

Gordon

[Nitrous]

Thanks Gordon,
I'll keep at it. If successful, might make an interesting post.
Doug

[femurat]

Your idea of pushing back the metal that was bent to retain the back plate is a good one. Bending it back again to reassemble the lock is easier than straightening it. You may end up with a bad looking but working lock. Go ahead and let us know how this experiment ends.

Good luck

[SnowyBoy]

Can't think of any method that would be non-destructive.

Gordon

I'll second this....

Gordon sent me some Master dial combo locks that are press fitted as I assume this is at the back. There's literally no way of prising it back to open it without the metal lip splitting and sheering off.

I tried the peel back method on a sacrificial lock and it failed horribly. Looks like it will have to be an in situ cutaway. At least I know where to drill

[Nitrous]

Can't think of any method that would be non-destructive.

Gordon

I'll second this....

Gordon sent me some Master dial combo locks that are press fitted as I assume this is at the back. There's literally no way of prising it back to open it without the metal lip splitting and sheering off.

I tried the peel back method on a sacrificial lock and it failed horribly. Looks like it will have to be an in situ cutaway. At least I know where to drill

I think that prying up the lip on a point by point method might be more inclined to split compared to spinning the entire lock in a lathe chuck, and trying to open it up using a metal spinning type tool.

The other difference is that unlike the lock you've described, these ABUS locks are aluminum bodied. At worst, I might need to anneal the lip before trying to pry it up. I've got an idea for a three point contact jig to use in my tailstock, but I have to wait for a 2" 3-jaw universal chuck and v-groove bearings to arrive.

Worst thing to happen is a waste of a little time.
I appreciate the feedback

Doug

[GWiens2001]

Let us know how it works out, Doug. Whether it is successful or not, we can all learn from each other.

Gordon

[SnowyBoy]

I've done both those masters now Gordon

I filed the edges away clean, then tapped the body and drilled the back plate so it screws together instead. Looks really good, pics tomorrow....

[GWiens2001]

I've done both those masters now Gordon

I filed the edges away clean, then tapped the body and drilled the back plate so it screws together instead. Looks really good, pics tomorrow....

Is drooling all over the place

Looking forward to the pictures!

Gordon