re-keying a padlock

[CHKNFKR]

Difficulty: 2 out of 10

Time to install: less than 5 minutes


Disclaimer: The Ranger Station.com, The Ranger Station.com Staff, nor the original poster are responsible for you doing this modification to your vehicle. By doing this modification and following this how-to you, the installer, take full responsibility if anything is damaged or messed up. If you have questions, feel free to PM the original poster or ask in the appropriate section of The Ranger Station.com forums.


Brief Explanation: I will be disassembling re-keying and reassembling an American Lock 5200 GL padlock for the purpose of having one key for EVERY padlock i own, thus saving space on my keyring and time hunting for the right key. this procedure should work on most American Lock or Master Lock brand locks. Pics were taken after this process was completed. I would also like to apologize for the quality of the photos, my cell phone is the only camera i own.

Tools Needed:
-Phillips screwdriver
-hand file *optional*
-steady hands


Parts Needed:
-Lock to re-key
-Old key
-New key
-Spare parts lock *optional*


Step 1: Select victim. In this how to i will be using an American Lock 5200 GL. The body of these locks are billet steel, the shackle is 5/16" diameter with 1 1/8" clearance. as a safety device (stupid proof) the key can only be removed when locked.

Step 2: Insert old key
Step 3: turn clockwise 90 degrees to unlock
Step 4: observe Phillips head bolt in top of lock body

Step5: Using Phillips screwdriver remove bolt. In order to remove bolt it may be necessary to hold the bottom plate (third pic) in place to prevent the retainer from spinning.

Step 6: remove key
Step 7: remove retainer

Step 8: remove bottom plate

Step 9: remove lock mechanism

Step 10: Insert old key into lock mechanism

Step 11: rotate key clockwise 180 degrees

Step 12: dump pins out

Step 13: remove old key
Step 14: line up pins on new key. your goal here is for all the pins to be flush. I was able to re use 4 out of 5 pins and the 5th was longer than necessary so I was able to file it down to size. if you aren't so lucky, this is where the "parts lock" comes into play *note* ignore the c-clip, springs and extra pins in this photo. While i had the lock apart i added perforated lifter pins to make the lock harder to pick. if you are just re-keying DO NOT remove c-clip and DO NOT remove inner shaft from sleeve!

Step 15: insert new key into lock mechanism

Step 16: insert pins into holes in shaft. If you did step 14 they'll be in order and all you have to do is pick them up one at a time and drop them in one at a time.

Step 17: turn key counterclockwise 180 degrees
Step 18: remove key
Step 19 -23: perform steps 5 through 9 in reverse order.
Step 24: test lock
Step 25: lubricate lock through 2 holes in lock, upper left and lower right. *note* some models may not have lube holes. in this case lube through keyhole and/or top of lock when opened. Lube is a matter of choice, i use 15/40 because it is abundant in the shop.

Step 26: Lock up your $hit!!!

Thanks for reading,
Dustin

 

[CHKNFKR]

If you lost the original key you will have to pick the lock in order to expose the bolt in the top of the lock body. once the lock is opened and the lock mechanism is removed things get fun. if the column is still partially turned, continue turning it until you can remove the pins and insert the new key. if the column is back in the lock position, you will either need to pick it once more or remove the c-clip and pull the column from the sleeve. when pulling the column, pull slowly and with the end that had the c-clip facing down onto a table or into a cup/bowl. as seen in the last picture, there are tiny lifter pins, tumbler pins (and shims if lock has a "master key") and tiny springs that will land anywhere but where you want them. assembly from this point is fairly straight forward and obvious. one spring down each hole, one lifter pin on top of each spring, reinsert column in unlocked position, install c-clip, continue from step 14.