I am re-keying a profile cylinder that is on a kwikset keyway. The problem is this is one of the old cylinders that have the brass caps tapped on top of the profile cylinder. It is not like the newer profile cylinders that you can use an allen wrench to remove the cap and repin the cylinder. Any suggestions on how to remove the caps and to replace them?
If it's the cylinder with factory pressed pin hole caps, then you need to remove the circlip from one side, pick that side of the cylinder until the bottom of the keyway is facing upwards (180 deg) then insert a purpose designed shim tool to hold up the top pins within the bible, then remove the plug from the shell with a hook pick to re-key and replace.
Think following tool... Plug and bottom pins come out and springs & top pins stay in place. Re-key and slide back in.
Leon Rowell
Cyrus Roll> I am re-keying a profile cylinder that is on a kwikset keyway. The problem
The way profile cylinders are configured are all over the map.
The only ones you need to deal with the caps are those that use a pin to retain the plug. If that is the case you only have 2 caps to drill out, the one that tops the retainer pin, and the one that has the detent ball.
To drill these I have found that the best way is to use a sharp bit that is about 1/2 of the diameter of the cap you are drilling.
This is going to be a small bit so set your drill press speed to very fast. A drill press is recommended for this even a $50 Taiwan cheapie is better than trying to do this with a hand held.
Use a sharp punch and lightly center punch the center of the plug. If everything works as the drill breaks through the cap it will suck the cap on to the flutes of the bit.
If that doesn't happen, then drill the hole with the tap drill for a 4-40 tap and cut some threads on the inside of the hole.
Usually the tap will coax the cap off, if not then thread in a 4-40 screw and pull.
Usually this will allow you to reuse the old cap. The reason you do not want to drill out the caps over the drivers is that these are often exposed when the cylinder is installed.
Some models of profile cylinders are a bitch but with patience and practice you can key them all.
If the cylinder you have is a real cheapie the pin spacing might be off and you might need to make appropriate adjustments on the key geometry if you can.
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