Yale 840 Repair Ideas?

[Robotnik]

As a previous post of mine alluded to, a portion of a large padlock lot I recently bought includes several Yale US Navy logo back locks.

I basically purchased the lot to get the one padlock pictured above. Very old USN 840; even has patent dates on top of case (1890 & 1891, Other Patents Pending ). Cut a key, and it opened...

...Then the plug fell out. So did the drivers, springs, and plug retainer. Somewhere along the line, the screws holding the retainer either backed out or sheared off. Disassembly for repair really isn't on the table; body pins are peened both sides, and drilling/replacing would be extremely destructive to this lock's aesthetic.

To make the best of the situation, and at least get a semi-functional display lock out of this, I've been able to reassemble with the first position driver pin installed. My issue is with retaining the plug once it's turned - I see no nondestructive way of doing this. Any ideas out there?

[GWiens2001]

Mill the plug's second pin channel sideways enough to allow the plug to turn to the unlock postion, to a depth of maybe .010", then put a peened-out key pin in the channel, tapping it down until it is flush with the bottom your milled section. Then put in a driver pin and spring in the second pin channel of the bible.

When you insert the plug and turn it to the locked position, the driver pin will drop down and lock itself in the channel, allowing the plug to turn, but not allowing it the plug to be withdrawn. Maybe you can mill it down only .005" and use a key pin instead of a driver pin, allowing you to remove the plug in the future if you so desire.

Sound doable?

Gordon

[Robotnik]

That sounds extremely doable. To streamline it a bit, am thinking I would mill a progressively deepening channel down to .010 or so. That way, when the plug's turned to unlock, the channel traps the plug in place, but since there's no retaining plate restricting it, I could turn the plug in the CCW direction (opposite of opening) for removal if neccesary.

Thanks for the idea!