MY ABLOY PROJECT (S)

[awol70]

here are two abloy locks that i opened ,using a semi-destructive method,leaving the locks in perfect working order,with very little visible damage.
i intend to make cutaways,and will update this post as i progress through this project

[jruther2]

This should be interesting.

[HiNtZ]

I'm somewhat worried about what tools you will be using to cut these locks away!?

Its a hard enough job for me & I've got a machine the size of a van!



Just go careful if you're using hand tools

Also, using a scribe to number the discs is an extremely good idea...... I had a peice of hot metal get stuck to my eyelid the other day whilst trying to modify an Abloy Protec locking bar and when i flinched I literally threw all the discs everywhere. Classics & profiles are okay, but the Disklocks & protecs are an absolute nightmare to rebuild thanks to the disc locking bars.

P.s Always wear goggles, I know I don't, but I'm an idiot!

[awol70]

wow! great job...
i was going to take the locks and measurements to a machine shop.
how do you remove the brass tube that the discs sit in?
i cant seem to get mine out..
(the part that rotates within the lock...)
thinking to myself : "boy i wish these had keys"
on a side note,the fist disc in is split in two,and forms a little "claw' mechanism that would frustrate pickers...

[HiNtZ]

wow! great job...
i was going to take the locks and measurements to a machine shop.
how do you remove the brass tube that the discs sit in?
i cant seem to get mine out..
(the part that rotates within the lock...)
thinking to myself : "boy i wish these had keys"
on a side note,the fist disc in is split in two,and forms a little "claw' mechanism that would frustrate pickers...

The disc basket should come out with no effort. If all the discs are out then jam one of your fingers in it and extract it. Be careful to mind the spring on the back of it though, its important and should be looked after.

If you mix up your discs or have trouble rebuilding it then give me a shout & I'll run you through the proceedure.

[awol70]

wow! great job...
i was going to take the locks and measurements to a machine shop.
how do you remove the brass tube that the discs sit in?
i cant seem to get mine out..
(the part that rotates within the lock...)
thinking to myself : "boy i wish these had keys"
on a side note,the fist disc in is split in two,and forms a little "claw' mechanism that would frustrate pickers...

The disc basket should come out with no effort. If all the discs are out then jam one of your fingers in it and extract it. Be careful to mind the spring on the back of it though, its important and should be looked after.

If you mix up your discs or have trouble rebuilding it then give me a shout & I'll run you through the proceedure.

ok,i tried what you said...the brass tube comes out halfway,then the shackle releases,
and it will come no further...am i doing something wrong?
thanks for your offer of help...=) i know i will be needing it,,,

[HiNtZ]

wow! great job...
i was going to take the locks and measurements to a machine shop.
how do you remove the brass tube that the discs sit in?
i cant seem to get mine out..
(the part that rotates within the lock...)
thinking to myself : "boy i wish these had keys"
on a side note,the fist disc in is split in two,and forms a little "claw' mechanism that would frustrate pickers...

The disc basket should come out with no effort. If all the discs are out then jam one of your fingers in it and extract it. Be careful to mind the spring on the back of it though, its important and should be looked after.

If you mix up your discs or have trouble rebuilding it then give me a shout & I'll run you through the proceedure.

ok,i tried what you said...the brass tube comes out halfway,then the shackle releases,
and it will come no further...am i doing something wrong?
thanks for your offer of help...=) i know i will be needing it,,,

Something certainly doesn't sound right. The shackle popped out because the balls arn't in contact with the disc basket anymore, that's normal though.

If you could post a picture of how far you have extracted it I will be able to tell you what's wrong. Is the locking bar still in there? That might be stopping it coming out further.

P.s Here's my Protec Cutaway..... I still have some cuts to do on the basket to expose the discs. Pics of that on monday

[uklockpicker]

This should be interesting.

Interesting to know how you got the abloy open keeping the disc's in good order ,

good luck with your cutaway

[awol70]

This should be interesting.

Interesting to know how you got the abloy open keeping the disc's in good order ,

good luck with your cutaway

look closely...really close...you will see my way in..

[awol70]

nope locking bars are out..
heres where the buck stops...
the basket (s) doesnt want to come out any further than this...( i dont want to force anything...)

[HiNtZ]

nope locking bars are out..
heres where the buck stops...
the basket (s) doesnt want to come out any further than this...( i dont want to force anything...)

I think I know the problem!

Where you had to drill it since you had no key it must have left a burr on the side wall which is catching on the basket.

Don't dorry about forcing anything, there is nothing else holding it in apart from possibly a little edge of metal around where you drilled.

Here's the Protec I've finished for a customer in Sweden. I hope he likes it

[awol70]

i dont think so, because they rotate freely,and my drill holes are almost a 1 mm away from the plug bore.
the drill bit never came into contact with the basket
(i actually preserved the threads and backed the set screw out,so it can be replaced...)
i am stumped...the basket drops freely out until what you see in the pic is exposed,and will come no further...
this is happening with both locks...i just dont get it...
what about wrapping pliers in a soft cloth?

[HiNtZ]

i dont think so, because they rotate freely,and my drill holes are almost a 1 mm away from the plug bore.
the drill bit never came into contact with the basket
(i actually preserved the threads and backed the set screw out,so it can be replaced...)
i am stumped...the basket drops freely out until what you see in the pic is exposed,and will come no further...
this is happening with both locks...i just dont get it...
what about wrapping pliers in a soft cloth?

Yeah, try pliers. But brass is soft, so you should be careful. I'm sure with a little bit of a pull should see it free.

[awol70]

i dont think so, because they rotate freely,and my drill holes are almost a 1 mm away from the plug bore.
the drill bit never came into contact with the basket
(i actually preserved the threads and backed the set screw out,so it can be replaced...)
i am stumped...the basket drops freely out until what you see in the pic is exposed,and will come no further...
this is happening with both locks...i just dont get it...
what about wrapping pliers in a soft cloth?

Yeah, try pliers. But brass is soft, so you should be careful. I'm sure with a little bit of a pull should see it free.

ok, i will try my best to not wreck anything...
thanks again for your help..

[Mike51691]

Wow great job hints, what kind of machine do you use to make them?