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How to open a 6 lever pancake lock (and not ruin it)

Need help fixing or installing a lock? We welcome questions from the public here! Sorry, no automotive questions, please.
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WE DO NOT ANSWER QUESTIONS ABOUT AUTOMOTIVE OR MOTORCYCLE LOCKS OR IGNITIONS ON THIS FORUM. THIS INCLUDES QUESTIONS ABOUT PICKING, PROGRAMMING, OR TAKING APART DOOR OR IGNITION LOCKS,

How to open a 6 lever pancake lock (and not ruin it)

Postby Gantry » 23 Jan 2017 18:14

Hey Guy's (and gal's), I just got a couple more 6 lever pancake locks and one of them was not working (knew this when I bought it). I've seen a few video's of people drilling out the lugs to get the lock apart but of course this pretty much destroys the lock. With some basic tools (and I really mean BASIC) you can open these locks up and then put them back together again. I'm not claiming this is the best way or the only way but it's what's worked for me. I start off with utility knife blades (sometimes stacking them on top of one another) to start to pry the seam apart. Remember what ever you do make sure you do it evenly all the way around the lock. You don't want to bend the face plate by putting to much strain on one side. Next I use a putty knife and then some screw drivers until I work the 2 halves apart. I hope this helps if you're looking to do something like this...
I guess I should add I use a hammer to "gently tap" these things into the seam, Take precaution as these things (especially the razor blades) can pop out! In the last picture you can see why the lock was not working as some of the springs are broken on the levers. Gantry

Image, Image, Image, Image, Image
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Re: How to open a 6 lever pancake lock (and not ruin it)

Postby billdeserthills » 23 Jan 2017 21:33

Having already disassembled a pancake lock this way I can tell you that it is so much easier
to make or buy a tool to pick and decode these type locks. Lauren showed how to make a
tool of this type, or you can buy the tool called a 'Dix Pick' from Robert Dix. The great thing
about this lock is the above tool will open it and at the same time measure the cuts needed
which makes it easier to file a key correctly
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Re: How to open a 6 lever pancake lock (and not ruin it)

Postby Squelchtone » 23 Jan 2017 21:41

Very nice photos and write up for those who have to take their locks apart and fix things like broken springs before the key works properly or to then make a key.

Thank you for posting!
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Re: How to open a 6 lever pancake lock (and not ruin it)

Postby jeffmoss26 » 24 Jan 2017 14:02

Lock Butcher Shop did a nice restoration on an Elm City 4 Lever for me - he used utility knife blades to open the lock body.
Here is the video:
https://www.youtube.com/watch?v=DCs-Q_3-Nas
"I tried smoking a blank once. I was never able to keep the tip lit long enough to inhale." - ltdbjd
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Re: How to open a 6 lever pancake lock (and not ruin it)

Postby tjohn » 24 Jan 2017 17:39

yep, good method, straight out of that video ^
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