Excaliber - there's nowt stranger than folk

[Griff]

A friend decided to show his wife my stratos whilst we were at the Classic Tour of Cornwall last night.
He then finds my house keys in the door pocket, and forces my bike lock key into the boot lock, to show her the engine!!! god knows what he was thinking, but according to management it was my fault, apparently leaving my house keys in the car meant it was my responsibility!!!!
The key is now firmly lodged, and showing no signs of being easily removed.
Has anybody had a similar experience? and what are the least damaging methods for removal? I'm hoping that feeler gauges down either side might release the key pauls, and allow me to slide it out.

[Stratos Fear]

- my sympathies Griff. If it will not pull out - and feeler guages dont work (which I suspect they wont) suggest snapping the key off and drilling out the lock barrel with ever increasing drill sizes. This will of course require a new lock to be fitted. Your friend has obviously done you a disservice !

[Azzo42]

I feel your pain ! Lots of WD40 and key jiggling. Pushing down on the barrel section at the same time 'may' help.

Some ice in a bag on the key to shrink it slightly.

[Griff]

Things have moved on a bit, it's now out, (various locksmiths said WD40 and pull it out with grips - which is exactly what I did) and I've recovered the parts. Still can't see how to get the barrel out of the casting, so I'm now looking for another one, any offers for either option?

[Guy Mayers]

Without dismantling my own....

I'd think that you need to remove the errant key from the barrel and insert the original key and then the pins should release and it ought to pop out. But wouldn't need to then would it? I note that there is sprung cover for the key, if that's caught on the side of the wrong one it may well be jamming it? The idea of a feeler gauge may have merit in moving the flap out of the way?

My next suggestion would be to remove the plastic head from the key and expose the steel body underneath, either drill a hole or weld something to it to allow you make a puller to ease it out slowly?

Guy

[ChrisCar6]

Jeez! How to lose friends! I feel your pain, but can't offer any suggestions - I can see the logic of Guy's theory of the flap that covers the slot.

[rutthenut]

A friend ... finds my house keys in the door pocket,
and forces my bike lock key into the boot lock, to show her the engine!!!

The key is now firmly lodged, and showing no signs of being easily removed.

An ex-friend now then?


As for removing that key from the lock barrel, no additional suggestions, I'm afraid.
Other than perhaps trying to lever it out, rather than trying to pull/wiggle it.
Lock on a vice (hopefully not so tight that breaks it) and try some sort of bar under the head of the key to apply force more directly to where it is needed. That is if force would solve it at all, which is not something you can be sure of.

[Azzo42]

Maybe heat the barrel or freeze the key ?

[Griff]

No John, friends are harder to find than boot locks, and I've calmed down now........

Bit of an update, the key is out. Having carefully looked at the barrel, there are/were two woodruff keyed slots on either side, these contained steel plungers and brass support cartridges, three on each side. One of the slots is pinned, this is because this side of the barrel also has springs behind the brass support cartridges, and is held in place by an interference fit steel pin. I removed the none pinned key, and the three plungers (there are also two blank holes), the key now came free, and I was able to insert the proper key, and lock/unlock the barrel.
On reassembly it became apparent that one of the plungers on the sprung side was misaligned, which will necessitate drilling out the pin and removing the woodruff key on that side (Note to self - make sure to do it on a large white towel, so as not to loose the springs, plungers, and cartridges).

I quickly disassembled it, moved the barrel into the unlocked position, and reassembled, so now I have a working boot closure, but it will need more work, a pillar drill to get the pin out, and making a new pin. Never mind, it's keeping the old grey matter ticking over.