I am restoring an old motorcycle (1967 Honda Dream) and some previous owner had gutted the cylinder (rather than take it to a locksmith to get a new key made) for the main ignition switch and all of the original internal pins and springs are gone. These switches are EXTREMELY rare and fetch insane prices when they do come available so there is considerable incentive to rebuild this lock. The ignition switch is also keyed-alike with the steering lock and I have a key that fits the steering lock so I should have what I need to get this lock functional again.
The pin holes measure 0.100" diameter and the top holes are blind and 0.200" deep so I will need hollow top pins to contain the springs. There are only 3 pins in this lock but security is not an issue due to the age of the machine (and not many people carry around 48 year old motorcycle keys!) so I really only need to create one pin. Unfortunately I can not find lock parts specifically for Honda and the best local locksmith says they can't help me so this is going to be a one-off DIY project.
I am thinking that I can buy K&S brass tube in 2mm size (0.0787") diameter for upper pins, silver solder on a solid end, and slip a suitable size spring in the tube to form the top pin.
For the bottom pin I can use 2mm solid brass rod and mark/cut the lengths by placing the key in the cylinder and marking the length at the surface of the cylinder.
I am not a locksmith, just a mechanically inclined amateur machinist, so I hope I am on the right path here!
Thoughts? Suggestions? Advice?

