The laminated padlock has always been a security product that actually looks secure. The gray metal, rough finished laminate body is built from a number of individually stacked, thick and solid looking hardened steel plates. The laminated body is held together with rivets. As a final security statement, the oversized rivet heads stand out from the top and bottom plates. What makes the laminated padlock even more impressive is that the larger they are, the greater the level of security they offer.
The laminated body padlock has been around for many years, visually unchanged for these years. And probably since its introduction, there has been a need to manufacture a re-keyable version of the laminated padlock.
To that end, ABUS has introduced the 41UK Series Re-Keyable Laminated Padlock, a double bolt locking padlock design that secures both the heel and the tool of the shackle. The 40 mm (1-½") wide laminated body padlock has four countersunk rivets that secure the 19 laminates in place. A 20th hardened steel laminate, the cover plate is riveted into position securing the lock cylinder once it has been combinated and installed. The keyway opening in the cover plate is minimal, forming a guard to resist drill attacks.
ABUS 41UK Series Padlocks are designed to be keyed to any bitting of the two available lock cylinders’ keyways. The 41UK padlocks are available with the ABUS RH5 keyway, a five-pin tumbler lock cylinder or an ABUS M1 keyway, a four-pin tumbler lock cylinder. The M1 keyway lock cylinders use pin tumblers, and spaces and depths compatible with existing padlocks.
To make re-keying practical, these 1-½" wide bodied laminated padlocks come without the cover plate secured by the four rivets. The lock cylinder and shackle spring are also not installed. In this condition, the shackle can be removed and a different length shackle can be installed. To increase the versatility of the 41UK Series padlocks, three available lengths of shackles have openings of 1", 1-½" or 2". ABUS shackles are white zinc plated hardened metal alloy.
Each 41UK complete padlock will contain:
• Padlock Body with shackle
(shackle not secured, it can be removed)
• 2 Hardened Steel Rivets
• Hardened Steel Bottom Plate
• Shackle Spring
• Lock Cylinder (first depth bitted)
For this article, I will assemble a 41UK/40 RH5 - OB padlock having the ABUS keyway five- pin tumbler lock cylinder. These padlock lock cylinders are bottom loaded. Each lock cylinder comes from the factory “0” bitted. To re-key, determine the new bitting. The 41UK Series use the smaller padlock style pin tumblers.
Spacing: Shoulder stop Cut-to-cut .122"
1- .157" 2- .280" 3- .402" 4- .524" 5- .646"
Depths Drop .0255"
1- .254" 2- .228" 3- .203" 4- .177" 5- .152"
Maximum Adjacent Cut Specification (MACS) is a three.
HPC 1200CM card is C112. Ilco Universal Code Machine card is 500.
To re-key the lock cylinder, the bottom pins must first be removed. Insert the operating key into the keyway and carefully rotate the plug one half revolution. In this position, the tops of the bottom pins should align with the openings in the bottom of the lock cylinder. Carefully remove the four or five bottom pins through the holes in the bottom of the lock cylinder. Once all of the bottom pins have been removed, do not rotate the plug.
Carefully remove the key. Insert the new key without moving the plug out of position. The plug pin chambers must line up with the openings in the bottom of the housing in order for the new bottom pins to load.
Insert the new bottom pins with the tips entering into the pin chambers first. This way the tips of the bottom pins will contact the key blade. The new bottom pins must align with the top of the plug, not the top of the housing. Use a suitable probe to press against each bottom pin to be certain they are at the proper depth. If any of the bottom pins are too short for the depth of cut, there will be a gap between the outer diameter of the plug and the height of the pin. If any of the bottom pins are too tall, they will extend out of the plug into the housing and will not permit the plug to be rotated.