Thinking about making a cutaway lock.

[jbearnolimits]

So I have a lock from Dollar Tree that I just can't seem to open. I'm thinking about cutting it open to see why. If I do then I want to use it as a cutaway practice lock after. I have not yet found a tutorial to show how I need to cut it open for that. Any links you can provide?

[GWiens2001]

First, how you would go about it depends on the lock. A picture of the lock and key would be helpful. I've seen cheap cheap cheap combination locks there. I've seen cheap cheap cheap warded locks there. And I've seen cheap cheap cheap pin tumbler locks there, in two varieties.

Gordon

[jbearnolimits]

It's a tool bench dollar tree lock.

[GWiens2001]

Look at the bottom of the lock. On the side of the keyway with the pins, scrape away the paint on the edge of the lock. You will find the caps used to close off the pin channels. Pull or drill out those caps (all of them on that side). The bottom four will also have springs, driver pins and key pins. (Keep them in order)

Once you have removed those, remove the next cap up. That one keeps the plug retainer pin in place. Once you remove it, you can pull out the plug.

Then there is the big one. Remove it, and you can remove the locking dogs and spring. Once those are removed, I think the shackle will come out.

Ready to mill!

If you don’t have much experience milling, I’d recommend re-installing the plug and plug retainer and a drill bit (dull side inserted in the pin channel) and taped in place. Use as large a drill bit as you can fit in the pin channel without forcing it. The reason for this is to keep the plug from spinning.

Now you can use those pin channel holes in the side to align your cutter with the pin channels. After cutting the three free pin channels (including the plug, since the retainer pin will keep it lined up), remove the drill bit and place it in another one of the pin channels. Tape it in place and cut the last pin channel.

Remove the drill bit, plug retainer pin and plug so you can clean up the cuts (if needed) and be sure the pins can move freely in the pin channels.

Now you can cut to show the locking dogs, shackle, shackle spring, even the plug retainer pin if you desire. Or not. It is your cutaway, you can cut or not cut whatever you please.

After all your cutting is done, and the lock is reassembled, take some brass rod and bevel it slightly to make new caps for the pin channels, retainer pin and locking dog channel. Tap them in lightly, then file fo smooth then out.

Good luck!

Gordon

[jbearnolimits]

Thanks, just one question. What did you mean by "the bottom 4"?

Edit: I had to read it again. I understand. Thanks