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7. Use emery paper to lightly sand away the burrs on the edges of the cuts. Wipe off the candle black from the original key. 8. Test the duplicate in the lock. Should it stick, blacken the duplicate and try it again in the lock. Breaks in the blackening will show where the key is binding. A light stroke with the file should correct this.
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After you learn how to read lever tumbler locks, you ll be able to make working keys without disassembling the locks. As you know, a lever tumbler lock keyway is narrow, and the view of the tumblers is further restricted by the trunnion. While this is a handicap, it can, in part, be overcome with the help of an appropriate reading tool. The positions of the lever tumbler saddles are one clue to reading the lock. The saddle of the lock can tell you quite a bit. The wider the saddle, the deeper the cut; the narrower the saddle, the shallower the cut. Using the reading tool, you will feel the different saddle widths to determine the cuts and develop some idea of the cuts and of the key shape. To do this properly, you must have an appreciation of the internal workings of the lock. Depth key sets can be useful when you are ready to cut the keys. Lever cuts are usually in 0.015- to 0.025-inch increments. Practice is required. Begin with a lock that has a window. If possible, obtain extra levers so you can change the keying of the lock at will. Raise each lever with the reading tool and determine the proper position for each one. Remember the general rule: A wide saddle requires more movement than a narrow saddle. Once you are satisfied that you have read the lock, disassemble it and examine the lever tumblers. You may have misread the tumblers but do not be disheartened. The only way to achieve competence in this skill is to practice. Other tumblers are designed with uniform saddle widths. Keying is determined by the positions of the gates in the tumblers. These locks can be quite difficult to read. Working with the reading tool, raise one of the levers as high as it will go. While this movement is not a direct indication of the depth of the key cut, it is important. The amount of upward movement establishes the minimum key cut; a shallower cut will jam the levers against the top of the lock case. In addition, the individual gates and traps are usually in some rough alignment. You will usually find that two are in almost perfect alignment. A cut for a lever that has the post on the upper half of the trap will be shallow; a cut for a lever that has its post on the lower half will be deep. A lever that has its gate in the intermediate position will require a key cut between these extremes. Once you have established the general topography of the cuts, refer to your set of depth keys for the exact dimensions. Established locksmiths have reference manuals that may simplify the work.
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The disc tumbler (or cam) lock gets its name from the shape of the tumblers. These are about as secure as lever locks and as such are superior to warded and other simple locks. However, disc tumbler locks are far less secure than pin tumbler locks. Disc tumbler locks are found in automobiles, desks, and a variety of coinoperated machines. Some padlocks are built on this principle. Because the cost of manufacture is very low, replacement is cheaper than repair. While similar to the pin tumbler lock in outside appearance and in the broad principle of operation, the internal design is unique. The disc tumblers are steel stampings arranged in slots in the cylinder core. Figure 6.1 shows a typical disc tumbler. The rectangular hole (or cutout) in the center of the disc matches a notch on the key bit. The protrusion on the side, known as the hook, locates the spring. The disc stack is arranged with alternating hooks, one on the right of the cylinder and one on the left. The lock is illustrated in Fig. 6.2.
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Figure 6.1 Disc tumbler lock in cross section. The position of the cutout determines the depth of the key cut.
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