Unlocking the Beauty: Restoring a Cabinet Door Lock and Crafting an Ornate Key
I was given a guilted door from what I presumed was an antique cabinet, the door was made of some kind of metal. I was told that the lock was broken and the locksmith wanted me to remove the ornate section of the lock that was a part of the door. Looking at it I decided that heating up the entire door to run the soft solder so I could remove the ornate lock cover would be a monumental pain and would be impossible to get back to the original condition with the lovely patina, so I told the customer something along the lines of this:
“I’m never going to return this to its original condition, the solder won’t flow the way I want it to.”, he understood the issue and we both had a moment to think. I then asked him to give me some time to figure out another way, maybe I could access the lock from the back of the door and do the repair from there, that way the repair won’t be visible from the front, the door doesn’t need to be re-guilted and re-patinated and I can work on the piece with nobody else interfering. He agreed to this, then started the journey.
Intrigued by the malfunctioning lock, I carefully cut out its back using a precision saw, a mere 0.25mm thick. What I discovered inside was disheartening—a missing bolt and a loose spring. To resolve this issue, I realised that I needed to remove the entire lock and fashion new internal components.
As time passed, the customer eagerly inquired about the progress of their door. I reassured them that I was meticulously crafting specialised tools to extract the lock with minimal disruption to the surrounding metal. Every effort was made to minimise material removal since any metal taken away would ultimately need to be restored. However, a new challenge emerged—I found that my current lathe was too small to create a steel arbour capable of holding the delicate 0.3mm circular saw required to free the lock from its frame.
With a few more weeks of patience, a stroke of luck smiled upon me. I acquired an old Myford ML7 lathe for the workshop, and without delay, I set to work turning the perfect arbour for the task at hand.
With the precision of a circular saw, I sliced through the lock, eager to uncover its secrets. As the rivets were ground away, a fascinating sight emerged—the remnants of the lock mechanism. There stood a pin, two sturdy posts securing the front plate and inner components, and the key's rotating axis. However, I couldn't help but notice what was missing—an absent bolt and cam. Although unaware of the full extent at the time, I instinctively knew that something crucial was amiss.
During the process of cutting out the lock, I noticed that progress was remarkably swift, surpassing my initial expectations. Initially, I had assumed the ornate lock cover was brass and soldered to the frame. To my surprise, it turned out to be an entire cast piece crafted from a white base metal, likely a tin alloy. This realisation meant that had I followed the initial instructions, the door would have melted under the intense heat required to remove the front of the lock from the frame.
Understanding the need to reverse-engineer the lock mechanism and devise a functional key system, I had already turned a tube with a pivot-sized hole and a flag to test the locking mechanism. However, this was before I discovered the missing innards. Determined to proceed, I meticulously created a detailed, scaled drawing of the lock, mapping out its features on paper. My quest for knowledge led me to scour the depths of the internet in search of a clear illustration, whether a GIF, video, or image, depicting the inner workings of such a simple deadbolt lock. To my dismay, the search yielded no results. The frustration mounted as I realised that, across the vast expanse of the internet, no one had produced a comprehensive guide to demystify this straightforward bolt mechanism.
As I carefully disassembled the larger lock I procured, I marvelled at its intricacy, consisting of four essential parts that harmoniously worked together:
Bolt with an Extruding Pin: This vital component engages with a cam, facilitating the smooth operation of the lock. Its purpose is to securely latch and unlatch the mechanism.
Cam with a Spring: The cam, equipped with a resilient spring, plays a crucial role in maintaining the lock's stability. It interacts with any part of the frame, ensuring that the lock remains securely in place, even when subjected to jolts or impacts.
Key and its Rotating Post: The key, revolving around a central post, serves as the gateway to unlocking the mysteries held within. Through its interaction with both the cam and the bolt, it grants access or denies entry.
As the key was inserted, a fascinating interplay unfolded—the bolt was pushed forward while simultaneously lifting the cam, deftly creating a path for unlocking. As the key reached a specific point, a cleverly positioned pin on the bolt allowed the cam to be pressed down by the spring's force, securely locking the bolt in position.
Comparing the features of the old lock with the new one obtained from Amazon, I discovered a remarkable similarity. However, their placement within the mechanism differed significantly. Armed with my scale drawing, I embarked on a journey of trial and error, using tracing paper to meticulously design a customised cam and bolt. It proved to be an intricate process, with each component requiring a snug fit. However, after a dedicated effort spanning a couple of hours, I emerged triumphant, presenting an innovative solution.
With the precise alignment of the key, cam, and bolt, I crafted a seamless locking mechanism, breathing new life into the old lock. The secrets of its intricate design had been deciphered, opening doors to both security and intrigue.
Reflecting on my experience, I couldn't help but ponder how I would approach the task differently in the future. If given the opportunity, I would undoubtedly utilise powerful design software like Solidworks to recreate the lock virtually. Although I lack proficiency in such programs, embracing the learning curve would undoubtedly save me countless hours of trial and error at the workbench.
It's amusing how, even after investing substantial time in designing the intricate components, I said aloud “even after all of that, it still might not work”, yet, in that very moment, another voice of determination whispered, “now all I have to do is make it!” So, I settled at the workbench, ready to embark on the hands-on journey.
To my surprise, the final crafted components bore little resemblance to the initial design. However, they retained the essential features, albeit shifted in their arrangement. It was a proud moment, witnessing my creation take shape. With meticulous care, I reassembled the lock, subjecting it to rigorous testing to ensure its flawless operation. Once satisfied with its performance, I delicately laser-welded the front plate back onto the posts.
Completing the meticulous restoration, the section of the door seamlessly blended with the surrounding metal, patiently awaiting the owner's decision on whether to embellish it with guilt. This triumphant achievement exemplified the harmonious fusion of design ingenuity and craftsmanship, a testament to unlocking success in the realm of lock restoration.
In addition to restoring the cabinet door, the owner expressed a desire for a bespoke ornate key. Well, who am I to resist such a request? Together, we collaborated on a design, which I scaled down and transferred onto brass by affixing a printed paper template. With precision, I delicately pierced out the intricate design. To add a touch of sophistication, the pierced design was mounted on shellac and engraved on both sides t add depth to the design. Finally, the key handle was carefully soldered to the functional part of the key. A patina was artfully applied, lending it a distinguished charm, and allowing it to blend in with the original patina of the cabinet, followed by a gilding process.
When I presented the finished key to the customer, their delight was evident. However, as with any bespoke creation, the price tag raised some eyebrows. To accommodate their preferences, I readily shortened the key by half an inch, ensuring their complete satisfaction. And there it was—an extraordinary key, the crowning jewel of a truly intricate cabinet door restoration.
Now, let's not forget the meticulous fitting of the door to the rest of the cabinet. The cabinet presented a unique challenge, as the tops of the doors were misaligned, impeding the smooth sliding of the bolt into the other door. Nevertheless, I approached this hurdle with careful precision, investing approximately 20 minutes in skilfully bending the door to ensure a perfect fit. Working with white metal proved advantageous, given its softness and malleability, requiring only a cautious touch to avoid any accidental breakage.
With every element meticulously attended to, the cabinet door restoration reached its pinnacle, showcasing a harmonious blend of artistry, craftsmanship, and meticulous attention to detail.