The Complete Book of Locks and Locksmithing 6th Edition

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Contents

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

iii
iv Contents

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.

ix

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
xi

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

A Short History of the Lock

1
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

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.