Drilling out an Ignition Switch

[junksaver]

I just wanted to post my experience with an ignition switch and no key. I just picked up a 67 stepside this past weekend with no key. I pulled out the passenger side lock cylinder to have a key made for it. Between pulling the cylinder, trying to find a locksmith and going to get the key made, I spent 2 1/2 hours. The locksmith made a key, but it wouldn't turn the cylinder. I'm not sure if he knew what he was doing, but I gave him $5 for his trouble. I brought the key back and it wouldn't work for the ignition either. I decided to drill the ignition out. If you are going to do this you better have patience. It took 1 1/2 hours. I had to drill 2 holes. If you look at the pictures I drilled out the center 1st starting with smaller bits and working my way up to 7/16". It still wouldn't come out. I drilled another hole directly below that one where the pins are located in the cylinder. I kept drilling with larger bits till the 2 holes connected. I was then able to put a paper clip in the small hole and twist it out with a screwdriver. If I had to do it over I would start by drilling a small hole in the bottom directly below where the key goes in. If you start there and work your way up to larger bits I think it would come out quicker.

[dmwphoto]

how easy would it have been if you had a working key?

[black_sheep454]

I have to do this to my swb, the guy I bought it from lost the key.
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[Ackattack]

Here is the funny thing about my experience the other day. Both my 68 and 69 keys are on the same key chain. I replaced the ignition/door key cylinders in both of them as part of each build. I have a little tag on the 68's key, so I can tell them apart.

Well the other day I stuck the 68's key into the 69 without thinking about it and turned the key and it started. The ignition kinda hung in the start position for a little bit (1/2) and thats what made me realize it was the wrong key. Usually, especially the original ignition cylinders, are so sloppy you can use a screw diver to start them (or in my 69
s case when I got it, an old steak knife....hence why I replaced it )

[blkcorvair]

You have to find an old time locksmith to handle them old keys. Alot of the newer guys just dont have the touch. I lost my 63 Corvair keys years ago. 20 minutes with the right locksmith and $80 later he punched a key using my glove box lock! I was impressed!

[too much stuff]

About 5 minutes with a sawzall from behind and you are done. Just cut it right off if you aren't saving it anyhow.

[rpmerf]

you probably could had picked the lock in under 5 min. Its hard to believe the locksmith couldn't make a working key....

[sanford66]

I just had to do this same thing a few days ago. The key broke off in the ignition on the 72 Custom Deluxe i just bought. I tried to get the lock cylinder out by turning the cylinder to the left past the acc. position, insert wire in tiny hole, etc.etc...fought it for about an hour, no luck. I finally went and got the 1/2 inch drill, hammer, and small punch and went after it. It came out in about 5 minutes after that, but i did have to replace the ignition switch because it got destroyed in the anger of the moment. Never underestimate the power of a big drill! Joseph