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- Cut out five pieces of wood 3/4″ thick, 2-1/4″ wide, and 4-1/2″ long. These will be stacked to make the lock body. When all five pieces are cut to size, number them one through five and mark the top of each piece, as in Figure 1.
- Position the platform so the 3/4″ hole at one end of lamination #1 is exactly in the right location. Use a piece of scrap wood the same size as a lock lamination to check hole location.
- All holes must be drilled straight into the wood. Lay out all holes on the top and bottom of lamination #1 as shown in Figure 3.
- Drill the 3/4″ shackle hole “A” all the way through lamination #1.
- Material Cutting. The wood I am using is teak wood which is 1" thick and I specially bought for this. Since the wood is cut from the bandsaw so that's why there are bandsaw marks over it and before cutting it I decided to plane down the wood.
- Glueing the Wood and Template. For glowing the wood I used PVA glue. After spreading the glue I decided to climb it so that if there are any visible ups and down left then with the help of clamping force I am able to close those gaps.
- Cutting the Material According to the Template. So to cut down that material if you don't have scrolls are then you can surely do it with the help of a jigsaw, that will also give you a better result.
- Sanding and Cleaning. For sanding, I use a Velcro pad in a grinder and use it to remove the rough surface from the workpiece. The grinder I am using is a variable speed grinder and running at slow speed so do not perform it with your regular grinder that would be dangerous.
- Layout. I used graph paper to lay out the concept and to try different configurations. This step was important to me in order understand the relationships between the parts in the assembly.
- Milling the Body. The first set of cuts are the channels that receive the tumblers. Second, the channels for the key and the bar, and in my case the safety key.
- Tumblers. The tumblers should be all cut at the same time to ensure that they are uniform The blanks should slide easily up and down in the channels with plenty of wiggle room to account for variations in the wood due to humidity etc.
- Bolt/Keys. Once the tumblers are set, the bolt and keys can be made to fit. I made several keys at once to have a few spares. Make sure the key and bar blanks slide freely in the lock body prior to cutting the teeth.
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Jul 28, 2014 · These unique projects for making working locks entirely from wood will present an an exciting challenge to woodworkers. “The Big Book of Wooden Locks” presents all of the most popular wooden ...
