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Can picking order be changed by replacing the plug?

Having read the FAQ's you are still unfulfilled and seek more enlightenment, so post your general lock picking questions here.
Forum rules
Do not post safe related questions in this sub forum! Post them in This Old Safe

The sub forum you are currently in is for asking Beginner Hobby Lock Picking questions only.

Re: Can picking order be changed by replacing the plug?

Postby Jacob Morgan » 3 Feb 2016 16:44

kwoswalt99- wrote:A lot of the inaccuracy of twist drills is caused by them not being sharpened perfectly.
After some searching, I still couldn't find what type of machine or fixture they drill the plugs and cylinders with.


That's a good point. Especially if a bit gets dull on an off shift and a foreman gives it a quick swipe on a grinder instead of sending it back to the tool and die shop.

I don't think it could be done with a gang drill (that woud drill all holes at once) as the holes are too close together. That would point to a single drill being used with a fixture holding the workpiece that indexes to each place to drill. Some of the problem will be with basic drill problems and positional error in the fixture / indexing mechanism. Guess would be that the drill bits are special made with a stepped cutter that would drill the hole and counter sink to debur at the same time. The condition of the cutting fluid could have an impact also.

If I ever get around to getting a surface plate I might have some fun by taking my surface gage and doing some measuring on different brands of lock to reverse engineer what tolerances they use.
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Re: Can picking order be changed by replacing the plug?

Postby cj101 » 4 Feb 2016 1:01

Some lock manufacturers used to drill the housing pins from the inner plug side (Dom, Zeiss Ikon).
They can probably control more precisely the position of the hole.
Most manufacturers however drill from the outside of the housing. Hence even a small angular error is amplified by the 15-20mm of housing length you have to drill.

I don't believe lots of manufacturers use reamers. The just drill with high speed with a slightly larger diameter. The lock will work perfectly smooth this way.
Unfortunately I cant inspect the holes under my cheap microscope at home. There you can see a difference.
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