turning down plug diameters

[cledry]

I have a job with 540 locks that are Sargent locks with US Lock restricted keyway cylinders. The customer uses SC4 Schlage on their other properties and wants to use that on this property. I will be using Ilco 1539 cylinders but need to turn the face diameter down to match the Sargent knobs. I know I can chuck them in a drill and hit them on the belt sander but this is less than ideal. So we have a small lathe, it will turn them down but it is time consuming. Any tips for speeding up the process from those who are experienced machinists?

[Raymond]

Have you considered a step drill to enlarge the knob hole? Depending on the construction of the knob this might work.
A tapered reamer could also work. Just mark it where to stop.
Also something tapered but smooth that will enlarge the hole without actual cutting, like a ring sizer or bolt installation/lineup punch.

I have done several with the drill and file.

Good luck

[demux]

I have, on occasion, fitted Illinois Duo's and Medeco cam locks to the internal locking mechanisms on filing cabinets and other office furniture (yes, I know I'm crazy, but it's fun). This usually requires turning down the face diameter. In the past I've done this on my bench grinder. I've gotten pretty good at doing this freehand and can get an almost-factory finish with some cleanup, but that is one or two at a time and I'm in no hurry. For several hundred you could probably make a jig though, indexed on the plug body. It'd be a bit of upfront work but once you had the jig made you could probably knock them out a lot faster than with a drill or a lathe.

[jeffmoss26]

only problem with using a step bit is that you could never put an OEM sargent cylinder back in.

[Safecrackin Sammy]

Dont reinvent the wheel...

Use the Kaba 1579 and it should be a drop in fit no mods needed.

But call Kaba tech sup and confirm with your Sargent model number

[cledry]

Have you considered a step drill to enlarge the knob hole? Depending on the construction of the knob this might work.
A tapered reamer could also work. Just mark it where to stop.
Also something tapered but smooth that will enlarge the hole without actual cutting, like a ring sizer or bolt installation/lineup punch.

I have done several with the drill and file.

Good luck

If it was just a few I don't have an issue with this, but on a job this size I would prefer not to modify the customer's locks.

[cledry]

Dont reinvent the wheel...

Use the Kaba 1579 and it should be a drop in fit no mods needed.

But call Kaba tech sup and confirm with your Sargent model number

Lead time is too long. Ended up using a lathe with a stop to speed things up.

[Safecrackin Sammy]

The lathe will do it.

Plus it looks like a 606 finish so you dont have an issue there

540 plugs, 539 plugs, 538 plugs..... (or beer on the wall)

Good luck with it.

[Squelchtone]

I have, on occasion, fitted Illinois Duo's and Medeco cam locks to the internal locking mechanisms on filing cabinets and other office furniture (yes, I know I'm crazy, but it's fun). This usually requires turning down the face diameter. In the past I've done this on my bench grinder. I've gotten pretty good at doing this freehand and can get an almost-factory finish with some cleanup, but that is one or two at a time and I'm in no hurry. For several hundred you could probably make a jig though, indexed on the plug body. It'd be a bit of upfront work but once you had the jig made you could probably knock them out a lot faster than with a drill or a lathe.

I like fun projects and have always wanted to install Medeco cam lock cylinders on my Jeep doors (just for fun), but never qot around to it. Plus, I have a remote starter and electric door lock/unlock, so I don't actually use my keys to unlock it. I would love to have the Medeco keyed ignition made by LT (LockTechnology) but their Chrystler CRL-1 model cam/tailpiece is not the correct shape to mate with the switch inside the steering column, and I think the retention location is different as well.

[Squelchtone]

Dont reinvent the wheel...

Use the Kaba 1579 and it should be a drop in fit no mods needed.

But call Kaba tech sup and confirm with your Sargent model number

Lead time is too long. Ended up using a lathe with a stop to speed things up.

Very nice work cledry! I wish I had a lathe.

[jeffmoss26]

looks good!

[cledry]

The lathe will do it.

Plus it looks like a 606 finish so you dont have an issue there

540 plugs, 539 plugs, 538 plugs..... (or beer on the wall)

Good luck with it.

Yes, 606 - US4 finish. Turning down 626 is OK too as the edges are hidden from view.

[BlueLock]

Nicely done. Your turned-down cylinders look great.