Adjusting unfitting replacement Key (Abus Bikelock)

[WizerAce]

It says no motorcycle lock question. May I ask a question about a bike lock? (Abus Bordo X Plus)

[demux]

I'm not a mod so can't speak with authority, but it would likely depend on the question. If it's to do with picking, bypassing, or otherwise opening the lock without the key, I suspect not. The general theme of the forum rules is to not educate bad guys how to do nasty things with other peoples' property, and a bike would likely fall under that.

If it's about general functionality, security features, recommendations, etc that should be allowed.

[GWiens2001]

What kind of question about the Abus Bordo lock? Nothing about destructive entry is permitted outside the advanced forums.

Gordon

[GWiens2001]

Hey guys,

I allready asked if im allowed to propose a question about my bikelock, but since its not of criminal nature, it should be fine.

So basically I lost my Keys. Luckily im an organized person. So i had no problem using my spare keys. Now its about reorganizing so that im prepared the next time it happens. I reordered Keys for my Abus Bordo X Plus Lock (with the CodeCard), but it turns out, it didnt fully fit. Like i could rotate the Key only for 140° (than the normal 180°).

So I asked Abus for a new one (thought it may be due to production errors. But still no luck... same problem again.

For me that means that the lock itself probably got modified over time. But i dont know where exactly I should look for...

Those are the keys.. (new one at the bottom:


So yeah can you help me with finding out what to grind on the new key so it fits to my lock?

I allready learned that those kinda locks have discs.. Are they always in the same order? Cuz if im able to rotate the key for 140° degrees, that should mean its probably one of the last discs not wanting to turn, right?

But i dont know what the last disc is anywas (dont have any lockpicking equip) (ok i could ask a friend, he got som cheap stuff for normal cylinders but i dont think we can use that on a disc lock right?) (also id appreaciate an easy solution without picking xd)

thanks in advance

[Squelchtone]

Merged into 1 topic, not sure why you started a new one..

Squelchtone

[GWiens2001]

Edited to show the picture in the post.

Looks like there is heavy wear on the old key. Perhaps a roll of a thin piece rolled over the warding. The old key still works properly, correct?

I would also suggest that you put the old key fully in the lock and mark where on the key it comes out of the keyway (the depth of the key in the lock) and do the same with the new key. Compare the distance it is in the lock measuring from the tip of the key.

Gordon

[stratmando]

Start with Gordon's advice, If mine, and key is useless, you can't hurt it, If you have a a good eye, good hands, small file, accurate measuring device, you might make it work. Worth a try.
I can see at least 2 places needing filing.
Good Luck.
Edit, forget measuring device, use the working key.

[GWiens2001]

Also try cleaning the lock. Hold the lock with the keyway facing down and spray upwards into the keyway with WD-40 to try flushing junk out of the lock.

If you have compressed air, then after flushing the lock, spray compressed air up into the lock to blow out remaining debris and WD-40.

Now spray some lubricant (Houdini, TriFlow or other lubricating spray).

Now try all the keys. If the new keys work, you are great. If only the old key works, do as Stratmando says and try to make the new keys match the old one.

I would avoid changing the old key unless cleaning the lock stops it from working (very doubtful).

Gordon

[WizerAce]

Thanks for the advice guys, i tried puring a bunch of WD-40 into the lock, but that didnt change anything.

Both keys enter the lock for the same lenght.

I tried filing the new Key but that didnt change anything too..

But now I notice, that with the new Key, theres more turning restistance in general. (until i hit the 140° barrier)

The old one turns as smooth as from the beginning.

[stratmando]

May have filed too much, their is a little trick used on guitar nuts that have been filed down to much. It is made with Baking Soda and Crazy glue. Turns hard as a rock. I always wondered/wanted to see if it could work on a pin Tumbler Key, like during Impressioning.

[WizerAce]

Oh thats an interestign idea.. but the greater resistance started occuring after I put the WD-40 into the lock.

Once I opened the lock and saw grease inside it. Too bad I cant replace that bec I have no grease at home. I just used a "Spray-Universal-Oil" (Ballistol)

Yeah xd

[stratmando]

If Original key is smooth turning, and New one binds, was thinking if filed too much, sidebar may not be all the way in the groove. Original still smooth?

[demux]

Just looking at those two keys, I can see several differences in the pics with just my eye. It's obvious that there's heavy wear on your old keys, which likely means heavy wear in the lock as well. Likely enough wear that the dimensions of your key and discs have deviated from factory specs by more than the allowed tolerance in at least one position. Problem is, when you ordered your replacement key it was cut to factory specs, which means it's now technically an incorrect key. I don't think any amount of cleaning and/or lubrication will help here. stratmando is correct, you need to make the new key match your old key. If you can find one in your area, your best bet would probably be to take your old key to an established locksmith that deals with this system and see if they can cut a key to match your existing one. If you fill in the Location section of your profile on this forum to let us know where about in the world you are, someone here might even be able to suggest such a locksmith.