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Millimeters 10.16 9.45 8.84 8.23 7.60 7.01 6.71 6.40 6.15 5.89 5.64 5.38 5.13 4.88 4.67
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Standard wire gauge number 7 71 2 8 9 10 11 12 13 14 15 16 17 18 19 20
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Inches 0.176 0.168 0.160 0.144 0.128 0.116 0.104 0.092 0.080 0.072 0.064 0.056 0.048 0.040 0.036
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Millimeters 4.47 4.27 4.06 3.66 3.25 2.95 2.64 2.34 2.03 1.83 1.63 1.42 1.22 1.02 0.91
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Warded Locks
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have to select a blank with a thick bit that you can file down to the correct taper. If you don t have a micrometer, Table 4.1, which shows standard wire diameters, can help you determine the approximate diameter of warded key blanks. You can take a standard piece of wire with a known diameter and compare it with any key blank. Also, use a drill to determine the approximate diameter of warded key blanks. Insert the pin of a blank into the hole that matches the blank s diameter.
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Duplicating a warded key by hand
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1. Select the proper key blank. 2. Wrap a strip of aluminum approximately 11 2 inches 21 4 inches or 21 2 inches around the pin and bit of the original key with one edge against the collar (Fig. 4.9). 3. Clamp the original key (wrapped in the aluminum) into a vise, bitting edge up. Ensure that the aluminum fits snugly around the key bit and pin. 4. Cut off excess aluminum around the bit of the key. Remove the aluminum strip and smoke the key with a candle. 5. Place the strip back on the bit and reclamp. 6. Using a warding file, cut down the aluminum strip not the original key until it is in the shape of the original key. Since the aluminum bends easily, use the file only in one direction away from you. The stroke should be firm and steady at first. As you file closer to the cuts of the original key, the strokes should be shorter and lighter. When the file just barely touches the original key and starts to remove the candle black, stop and go no further. If the candle black is removed and the shiny surface of the original key is revealed, you have filed too deeply. 7. Fit the aluminum strip onto the key blank. 8. File down the exposed areas on the bit until it matches the outline of the aluminum strip. Be careful not to cut into the strip. Again, use shorter and lighter strokes as you get closer to finishing each cut.
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Figure 4.9 File into the aluminum strip
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in the direction shown.
Four
9. If the original key has a side groove that matches a keyhole ward, this too must be cut. Use another strip of aluminum. If the original key has two grooves, you must wrap the strip around the bit so that both grooves are covered. 10. Using a scriber, scratch the metal strip to indicate the top and bottom of the groove(s). Fit the strip onto the key blank and mark the positions of the groove(s) on both ends of the bit. By connecting the marks with lines, you know exactly where to file. 11. To determine the depth of a groove cut, put one edge of a metal strip into the groove of the original key and scribe the depth of the groove on it. This mark will be your depth guide when filing the groove on the duplicate key.
Pass keys
Skeleton-type pass keys (master keys) are sold in variety stores. These keys will fit many old locks and more than a few new ones. As such, they are convenient. However, few locksmiths stock them. Why Many locksmiths believe the ethics of the profession forbid it. You certainly do not want to supply someone with a key that could open her neighbor s lock. Nor should you duplicate a pass key without authorization from the owner. Be leery of a customer who wants a key duplicated but with additional cuts. Locksmiths have lost their licenses for less. Don t let it happen to you.
Lever Tumbler Locks
Lever tumbler locks (or lever locks) have many uses in light security roles. Available in a variety of sizes and shapes, these locks are found on desks, mailboxes, lockers, bank deposit boxes, and other devices. Figure 5.1 illustrates a popular example of a lever tumbler lock. The circular window on the back of the case aids the locksmith by revealing the heights of the levers, so you aren t forced to dismantle the lock. Thanks to the window, it is relatively easy to make a key in the blind. Parts A lever tumbler lock has six basic parts:
Cover boss Cover Trunnion Lever tumblers (top, middle, and bottom) Bolt (bolt stop, notch, and post) Base These parts are shown in Fig. 5.2.
Operation This lock requires a standard flat key. When the key is turned, the various key cuts raise corresponding lever tumblers to the correct height. As the levers are raised, the gates (Fig. 5.3) of the levers align and release the bolt. The bolt stop
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