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Re: How To Make New Handles For A Picklock

PostPosted: Fri Nov 21, 2014 2:08 am
by Rubens Blades
Now all of your holes are drilled and you have pins in place,so you can sand the sides of your handles flush with the liners.

Do this any way you can without digging into the brass on the liners.

Re: How To Make New Handles For A Picklock

PostPosted: Fri Nov 21, 2014 2:08 am
by Rubens Blades
When you are all done,it should look something like this. If you are using a different handle material,such as horn,now is the time you want to shape it the way you want it and polish it.

Re: How To Make New Handles For A Picklock

PostPosted: Fri Nov 21, 2014 2:09 am
by Rubens Blades
Now you need to figure out how far the safety needs to travel to stop the button. In this case,it needs to go forward about 3/4 of the button.

Re: How To Make New Handles For A Picklock

PostPosted: Fri Nov 21, 2014 2:10 am
by Rubens Blades
Now you have to mark out on the bottom of your handle material how far the safety needs to travel back to clear the button,so the knife can fire,as well as how far forward to keep the button from firing the knife.

Re: How To Make New Handles For A Picklock

PostPosted: Fri Nov 21, 2014 2:11 am
by Rubens Blades
Now you need to make your safety slot. I use Dremel cut off wheels for this and you can compare the thickness of your safety to see which wheel to use. They come in standard and heavy duty. The heavy duty cut off wheels are thicker.

You want to make your slot the same depth as the safety itself. I do this by eye,and have no real tricks,just be careful and go slow and keep checking.

You will also want to make the slot go a little past your rear line,as you can see in the pic. If you stop at the line you will have a round area and the safety will not be able to travel far enough back.

Re: How To Make New Handles For A Picklock

PostPosted: Fri Nov 21, 2014 2:12 am
by Rubens Blades
So now you have the slot all done underneath and are probably trying to figure out how to make the slot at the top of the handle.

I do this by drilling a very small hole at the lowest mark. This is a 1/64 bit.

Re: How To Make New Handles For A Picklock

PostPosted: Fri Nov 21, 2014 2:13 am
by Rubens Blades
Flip the handle over,and keeping the same marks from the bottom,as well as the hole you just drilled and you know exactly where your safety slot needs to be.

Re: How To Make New Handles For A Picklock

PostPosted: Fri Nov 21, 2014 2:14 am
by Rubens Blades
To make this slot I save my worn down cut off wheels. They are much smaller than when new, and I keep various sizes on hand for different slots.

If you do not have a worn down cut off wheel,take a new one and grind it on a scrap piece of metal until it wears down to the size you need.

The slot will not be perfect and will need to be cleaned up a little. I do this by using a small scroll saw blade that is about the same thickness of the dremel cut off wheel. In this case it is a Ryobi 15 TPI ,5 inch scroll saw blade that is .0197" thick.

Re: How To Make New Handles For A Picklock

PostPosted: Fri Nov 21, 2014 2:15 am
by Rubens Blades
Now that the slot is all cleaned up,check your fit on your safety and it should look like this.

Re: How To Make New Handles For A Picklock

PostPosted: Fri Nov 21, 2014 2:22 am
by Rubens Blades
Now it is time to pin the handles to the liners. I do this by running the pin all the way through and then snipping off the ends of the brass rod.

Next I sand the pin flush with the inside of the liner. Then I sand the pin at the top of the scale leaving what you see in the pics.