The Complete Book of Locks and Locksmithing
Bill Phillips
Sixth Edition
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DOI: 10.1036/0071448292 Professional
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Foreword by Greg Mango, Editor, The National Locksmith ix Preface xi Acknowledgments xii
Chapter 1. A Short History of the Lock 1 Who Invented the Lock? 1 Egypt 1 Greece 2 Rome 2 Europe 5 England 6 America 9 Early American Lock Companies 12 A Brief History of Automobile Locks in the United States 13
Chapter 2. Tools of the Trade 15 Electric Drills 15 Cordless Drills 17 Key Cutting Machines 18 Workbench 18
Chapter 3. Types of Locks and Keys 37 What Is a Lock 37 Lock Names 38 Lock Grades 46 Key Types 47 Key Blank Identification 48 Key Blank Examples 50 Look-Alike Keys 54 Neuter Bows 57
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Chapter 4. Warded Locks 59 Types 59 Construction 60 Operation 62 Repair 62 Warded Keys 65
Chapter 5. Lever Tumbler Locks 69 Parts 69 Operation 69 Repairs 72 Varieties of Lever Tumbler Locks 72 Lever Tumbler Lock Keys 80
Chapter 6. Disc Tumbler Locks 87 Operation 88 Disassembly 89 Keying 89 Security 89 Cam Locks 89 Reading Disc Tumbler Locks 90 Double-Bitted Disc Tumbler Locks 99
Chapter 7. Pin Tumbler Locks 103 Construction 103 Disassembly 108 Assembly 111 Choosing a Pin Tumbler Lockset 112 Pin Tumbler Cylinder Mortise Locks 113 The Cylinder Key 117
Chapter 8. High-Security Mechanical Locks 125 Underwriters Laboratories Listing 125 Key Control 126 Lock and Key Patents 126 Types of High-Security Mechanical Locks 127
Chapter 9. Masterkeying 149 Coding Systems 149 Master Key Systems 149 Masterkeying Warded Locks 150 Masterkeying Lever Tumbler locks 150 Materkeying Disc Tumbler locks 153 Masterkeying Pin Tumbler Locks 154 Contents v
Developing the Master Key System 158 Master Key System Variations 163 A Simple Master Key System 171
Chapter 10. Detention Locks and Hardware 175 Types of Locks 175 Electric Strikes 176 Choosing the Right Equipment 176
Chapter 11. Buying and Selling Safes 183 Types of Safes 183 Safe Styles 184 Installing an In-Floor Safe 185 Moving Safes 187 Special Safe Features 187 Underwriters Laboratories Fire Safe Ratings 187 Underwriters Laboratories Burglary Safe Standard 188 Selling More Safes 190
Chapter 12. Keyed Padlocks 195 Choosing a Padlock 195 Warded Padlocks 196 Wafer Disc Padlocks 198 Pin Tumbler Padlocks 199 Major Padlock Manufacturers and Their Products 201 Helpful Hints 215
Chapter 13. Home and Business Services 217 Common Problems and Troubleshooting 217 Corbin Cylindrical Locksets 219 The MAG Ultra 700 Deadbolt 234 M.A.G. Engineering and Mfg., Inc. 236 The Schlage G Series Lockset 245 Strike Plates 268 M.A.G.’s Install-A-Lock 272 Exit Alarm Locks and Panic Bar Deadlocks 276
Chapter 14. Lock Picking and Impressioning 297 Picking Pin Tumbler Locks 297 Why Pin Tumbler Locks Can be Picked 297 Raking 300 Using a Pick Gun 301 Lock Picking Tips 301 Picking High-Security Cylinders 305 vi Contents
The Need for Practice 306 Impressioning Locks 306 Other Useful Equipment and Supplies 307 Popular Impressioning Technique 308 Alternative Impressioning Method 310 Problems with Impressioning 310 Impressioning Practice 311 Warded Bit-Key Locks 311
Chapter 15. Servicing Automotive Locks 313 Vehicle Identification Numbers 313 Basics of Automobile Lock Servicing 313 Door Locks 315 Ignition Locks 316 Glove-Compartment Locks 317 Trunk Locks 318 Transponders 319 American Motors Corporation 320 Audi 321 BMW 321 Chrysler 321 Datsun 322 Ford 322 General Motors 324 Servicing General Motors Vehicles with VATS 327 Honda 330
Chapter 16. Opening Locked Cars 331 Opening Locked Cars 331 Car-Opening Techniques 336 The Long-Reach Tool 338 Car-Opening Dispatch Procedure 345
Chapter 17. Emergency and Forced Entry Procedures 347 Drilling Pin Tumbler Locks 347 Cylinder Removal 348 Window Entrances 350 Office Locks 350 Doors 353 Unlocking Thumbcuffs, Handcuffs, and Legcuffs 355 Forced Entry 359
Chapter 18. Combination Locks 361 Parts 361 Manipulation 362 Contents vii
Drilling 363 Changing Combinations 363 Other Keyless Locks 368
Chapter 19. Electrical Access and Exit Control Systems 401 Electric Release Latch Strikes 401 Circuitry 411 Electric Door Openers 418 Electrified Mortise Locks 429 Electrified Knob Locks 432 Electromagnetic Locks 441 Electrical Keyless Locks 449 Key-Actuated Switches 455
Chapter 20. Working as a Locksmith 461 Finding a Job 461 Business Considerations 472 The Locksmith and the Law 483
Chapter 21. Key Duplicating Machines 487 Critical Design Factors 487 Framon’s DBM-1 Flat Key Machine 490 Ilco’s KD50A 493
Chapter 22. Test Your Knowledge 501 Registered Professional Locksmith Answer Sheet 509
Chapter 23. Making Locks by Hand 511 A Warded Bit-Key Lock with Deadbolt 511 English Iron Rim Lock 521
Chapter 24. Answers to Frequently Asked Questions 525
Appendix A. Manufacturers 533 Appendix B. Locksmith Suppliers’ Profiles and Addresses 545 Appendix C. Miscellaneous Important Addresses, Phone Numbers, Web Sites 549 Appendix D. Locksmithing Schools and Training Programs 553 Appendix E. Depth and Space Charts 559 Index 571 About the Author 589 To Patricia Bruce not only because she is a good friend and a fine writer but also because she listened . . . and listened . . . and listened. Foreword
The knowledge, skill, and expertise of any true professional often can be gauged by the library of literature that he or she keeps and has read. In the often mysterious, secretive, and intriguing world of locks and locksmithing, no true professional, aficionado, or curiosity seeker would be without The Complete Book of Locks and Locksmithing, 6th edition. Just as the title states, this is by far the most complete, informative, and all-encompassing piece of literature ever assembled between two covers on this subject. As a 21-year veteran of the locksmith trade, I can tell you that the scope of this book (covering one of the oldest trades known to humans) is much broader than one would think. The locksmith profession is also often one of the most challeng- ing and rewarding. There are few things in life that are dearer to anyone than the security of their family and worldly possessions. Having the knowledge and ability to instill and incorporate security, eliminating the helpless sense of vulnerability, is what locksmithing is all about. However, to accomplish this task, knowledge of all the available security devices and an intimate knowledge of their operation and applications are necessary. Enveloping yourself within the pages of this book cer- tainly will set you on the right path. The test of any good source of information is that it is one that you refer to again and again. This is sure to be the case with The Complete Book of Locks and Locksmithing, 6th edition. This is so much more than a “book” on locks and lock- smithing. It is an encyclopedia of locks and locksmithing. It is a reference manual from which anyone at any level of skill or experience can glean a wealth of infor- mation. It is an informative, well-studied, impeccably presented piece of work that required an exhaustive amount of research, cataloging, organizing, and writing to assemble and publish. This is a daunting task, demanding the talents of a skilled writer and locksmith, and Bill Phillips certainly possesses the necessary require- ments to accomplish it. Bill Phillips is a knowledgeable locksmith and talented writer. He is one of those individuals who possess the rare ability to make a wide variety of compli- cated topics enjoyable to read and easy to understand. This is a sure sign of a talented, versatile writer. When Bill Phillips asked me to write this Foreword, I was honored and flat- tered. I am privileged to have Bill Phillips’ name included on my masthead of contributing writers. As editor of The National Locksmith magazine, I cherish his contributions on security-related topics. The National Locksmith is the oldest and most respected locksmith trade journal in the industry, serving locksmiths and security professionals since 1929. This monthly magazine has a group of the most experienced and well-respected writers in the field of locksmithing. In 2004, Bill Phillips became one of the distinguished elite to join The National Locksmith’s out- standing team of contributing writers, and I couldn’t be more excited to have him.
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Copyright © 2005 by Bill Phillips. Click here for terms of use. x Foreword
Bill Phillips and The National Locksmith share one common goal—to provide informative, timely, useful, and cutting-edge information to beginning and experi- enced locksmiths. Bill Phillips accomplishes this through his writings and personal presentations. The National Locksmith does it through its monthly publica- tion, as well as books, software, The Institutional Locksmith magazine, the www.TheNationalLocksmith.com Web site, and membership organizations such as the National Safeman’s Organization (NSO) and the National Locksmith Automobile Organization (NLAA). Few people have as much knowledge or experience writing about locks or lock- smithing as Bill Phillips does. He has written for most of the locksmith trade journals, many general consumer magazines, and the World Book Encyclopedia (the “Lock” article), and he has been published by one of the most respected and distinguished publishing houses—McGraw Hill. Those are claims and accom- plishments few others can make. If you want to become a locksmith or are just fascinated with locks and want an insider’s view, you won’t find a better book than The Complete Book of Locks and Locksmithing, 6th edition. It’s a tremendous treasure of information that you will refer to for years to come.
Greg Mango
Greg Mango is a 21-year veteran of the locksmith industry. He is currently editor of The National Locksmith magazine and director of the National Locksmith Automobile Organization (NLAA). He has authored numerous security-related articles for multiple publications over the last 15 years and his monthly “Mango’s Message” editorial column is read by thousands. Preface
I’ve read a lot of great reviews for earlier editions of The Complete Book of Locks and Locksmithing. For the last edition, the most memorable one came from Alan T. Peto, who works for the Las Vegas Metropolitan Police Department. He wrote This is a great “catch-all” book about locksmithing. Although it looks like it is designed for beginners, it still has invaluable information on a variety of locks, etc., so it will remain in your shop for years to come. . . . The book is also invaluable to homeowners . . . and anyone who wants to know more about locks, safes, and more! Mr. Peto’s book review summed up what The Complete Book of Locks and Locksmithing has been about since the first edition in 1976. Today, it’s the world’s best-selling locksmithing book, and it is used often as a textbook in locksmithing schools and programs. I know what beginning locksmiths and seasoned professionals want from a book. My first exposure to locksmithing was through reading books. In those days, the books that were available didn’t provide much practical information, so I took a couple of locksmithing correspondence courses—which were virtually worthless. I ended up moving to New York City for about a year to study at the National School of Locksmithing and Alarms. That was the best investment I ever made, because I learned a lot. A certified master locksmith, who was an avid writer of locksmithing articles, hired me right out of school. He taught me some things, but we never did get along. We were both opinionated, and we often had toe-to-toe shouting matches about how things should be done. Therefore, we parted ways. I worked for anoth- er shop for a while, and then I started my own shop. I’ve been working for myself ever since. Over the years, I went on to write 13 security books and hundreds of articles. My work appeared in Consumers Digest (reviewed over 150 door locks, safes, and car alarms), Keynotes (the trade journal of the Associated Locksmiths of America), the Los Angeles Times, Locksmith Ledger International (was a contributing editor), The National Locksmith (am a contributing writer), Safe and Vault Technology (was a contributing editor), and many other periodicals. I also wrote the “Lock” article for the World Book Encyclopedia—the world’s most read print encyclopedia. I love to teach, and I love to learn. I’m constantly learning new things about lock- smithing, which is why I felt the need to revise this book. This sixth edition contin- ues the tradition of being heavily illustrated and providing lots of useful information about locks and locking devices. I updated every page and added four new chapters— including one on automotive lock servicing and one on lock picking and impression- ing. I added information about selling safes and finding a job as a locksmith. This edition includes a new chapter on frequently asked questions (Chap. 24) with candid answers to lots of questions such as: Do I need to be licensed or
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Copyright © 2005 by Bill Phillips. Click here for terms of use. xii Preface
certified to work as a locksmith? What can I do if a customer refuses to pay me? How can I get started writing about locksmithing? What are the best lock- smithing resources on the Internet? Are pick guns worth the money? Which are the best trade journals? What keys are illegal to duplicate? I’ve also included a new Registered Professional Locksmith (RPL) test that you can complete to earn a certificate. The certificate can help you to find work and will allow you to enter restricted areas on the Internet. Also, four appendixes are included. The resources all have been updated with current addresses, Web sites, telephone numbers, and so on. If you have questions or comments about the book, contact me at Box 2044, Erie, PA 16512-2044, or e-mail me at [email protected].
Acknowledgments This sixth edition of The Complete Book of Locks and Locksmithing is the result of help from a lot of people, too many to mention each by name. I appreciate everyone’s help. Special thanks go to Greg Mango, editor of The National Locksmith; Earl Halls, president of Adesco Safe Company in Paramount, California; Gordon Little, president of Gordon Safe and Lock, in Houston, Texas; Joe Esposito, of Liberty Lock & Safe in Las Vegas, Nevada; Peter Burns, inven- tor of “The Bolt” High Security Lock; Billy B. Edwards, CML (“TheLockMan”); Thomas F. Hennessy, curator of the Lock Museum of America; Alex Krai; Bill Morrison; Alan T. Peto; Alice Petty; and Donald Streeter. Thanks also go to all the readers of prior editions who shared their thoughts about the book with me. Their criticisms and suggestions were invaluable in making this edition. The following companies were especially helpful in providing technical informa- tion: A-l Security Manufacturing Corp., Abus Lock Co., Adams Rite Manufacturing Co., Alarm Lock Systems, Inc., Arrow Lock, Belwith International, Ltd., Black & Decker U.S. Power Tools Group, Dominion Lock Co., Folger Adam Co., Framon Manufacturing Co., Inc., Gardall Safe Corp., Ilco Unican Corp., International Association of Home Safety and Security Professionals, Keedex Manufacturing, Kryptonite Corporation, Kustom Key, Inc., Kwikset Corp., Lock Corporation of America, M. A. G. Engines & Manufacturing, Inc., Makita U.S.A., Inc., Master Lock Co., M. K. Morse Co., Medeco Security Locks, Milwaukee Electric Tool Corp., Monarch Tool and Manufacturing Co., the National School of Locksmithing and Alarms, Porter Cable Corp., Presto-Matic Lock Co., R&D Tool Co., Rofu International Corp., Schlage Lock Co., Securitech Group, Securitron, Security Engineering, Inc., Sentry Door Lock Guards, Sentry Group, Simplex Access Controls Co., Taylor Lock Co., Trine Consumer Products Division, Square “D” Co., and Vaughan & Bushnell Manufacturing Co. I also appreciate the support I received from family and friends, including Janet L. Griffin, Merlynn Smith-Coles, and Jonathan Gavin for his help with photographs. Special thanks also go to Cary Sullivan and Carol Levine, my editors at McGraw-Hill. Bill Phillips
Copyright © 2005 by Bill Phillips. Click here for terms of use. Chapter 1 A Short History of the Lock
This chapter traces the development of the lock from earliest times to the pres- ent, focusing on the most important models. Every locksmith should be famil- iar with them because they form the building blocks for all other locks. Many of the lock types and construction principles mentioned here are looked at in more detail in later chapters. This is a quick overview to help you better understand and appreciate the world of locks.
Who Invented the Lock? The earliest locks may no longer be around, and there may be no written records of them. How likely it is for old locks to be found depends on the mate- rials they were made from and on the climate and various geological condi- tions they have been subjected to over the years. There is evidence to suggest that different civilizations probably developed the lock independently of each other. The Egyptians, Romans, and Greeks are credited with inventing the oldest known types of locks.
Egypt The oldest known lock was found in 1842 in the ruins of Emperor Sargon II’s palace in Khorsabad, Persia. The ancient Egyptian lock was dated to be about 4000 years old. It relied on the same pin tumbler principle that is used by many of today’s most popular locks. The Egyptian lock consisted of three basic parts: a wood crossbeam, a verti- cal beam with tumblers, and a large wood key. The crossbeam ran horizontal- ly across the inside of the door and was held in place by two vertically mounted wooden staples. Part of the length of the crossbeam was hollowed out, and the vertical beam intersected it along that hollowed out side. The vertical beam contained metal tumblers that locked the two pieces of wood together. Near
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Copyright © 2005 by Bill Phillips. Click here for terms of use. 2 Chapter One
the tumbler edge of the door there was a hole accessible from outside the door that was large enough for someone to insert the key and an arm. The spoon- shaped key was about 14 inches to 2 feet long with pegs sticking out of one end. After the key was inserted in the keyhole (or “armhole”), it was pushed into the hollowed out part of the crossbeam until its pegs were aligned with their corresponding tumblers. The right key allowed all the tumblers to be lift- ed into a position between the crossbeam and vertical beam so that the pins no longer obstructed movement of the crossbeam. Then the crossbeam (bolt) could be pulled into the open position. To see how the lock looked and operat- ed see Fig. 1.1.
Greece Most early Greek doors pivoted at the center and were secured with rope tied in intricate knots. The cleverly tied knots, along with beliefs about being cursed for tampering with them, provided some security. When more security was needed, doors were secured by bolts from the inside. In the few cases where locks were used, they were primitive and easy to defeat. The Greek locks used a notched boltwork and were operated by inserting the blade of an iron sickle- shaped key, about a foot long, in a key slot and twisting it 180° to work the bolt (Fig. 1.2). They could be defeated just by trying a few different-size keys. In about 800 B.C.E. the Greek poet Homer described that Greek lock in his poem The Odysseus: She went upstairs and got the store room key, which was made of bronze and had a handle of ivory; she then went with her maidens into the store room at the end of the house, where her husband’s treasures of gold, bronze, and wrought iron were kept.…She loosed the strap from the handle of the door, put in the key, and drove it straight home to shoot back the bolts that held the doors.
Rome Like the Greeks, the Romans used notched boltwork. But the Romans improved on the lock design in many ways, such as by putting the boltwork in an iron case and using keys of iron or bronze. Because iron rusts and corrodes, few early Roman locks are in existence. But a lot of the keys are around. Often the keys were ornately designed to be worn as jewelry, either as finger rings or as necklaces using string (because togas didn’t have pockets). Figure 1.3 shows some early Roman finger rings. Two of the most important innovations of the Roman locks were the spring- loaded bolt and the use of wards on the case. The extensive commerce during the time of Julius Caesar led to a great demand for locks among the many wealthy merchants and politicians. The type of lock used by the Romans, the warded bit-key lock, is still being used today in many older homes. Because the lock provides so little security, typically it’s found on interior doors, such as closets and sometimes bedrooms. A Short History of the Lock 3
Cutaway view of vertical beam with tumblers
Extra key
Keyhole (or “arm hole”)
Key in hollowed out part of bolt, lifting tumblers
Vertical wooden staple
Figure 1.1 Ancient Egyptian locks relied on the pin tumbler principle that many of today’s locks use. 4 Chapter One