Securing the Pannier Lock Cylinder
In a previous post I demonstrated how insecure a locked pannier was and how easily the lock cylinder could be removed allowing the pannier to be taken off the bike or access to the contents - This post demonstrates how to secure the lock cylinder to prevent removal and improve pannier security.
Remove the handle and locking assembly from the Pannier.
From inside undo the screws and it comes out easily.
Remove the Lock Cylinder - Its not hard, you can make the tool to remove lock cylinder from a used or new hacksaw blade as depicted.
Click on the picture and it will play a video and show how to remove the Lock Cylinder from the handle assembly using the above tool.
Drill a hole through the bottom, drill through the aluminum backing as well - try and make it central - the hole only needs to big enough for the screw to pass through without binding.
Enlarge the hole in the backing plate to accept the screw head - be careful not to drill into the plastic underneath.
Drill a hole in the end of the lock cylinder to suit the size screw you intend to use, ideally drilling and tapping a thread would be the best method but in this example I used a self taping screw.
Be very careful here not to over drill as it will damage the key cylinder and your key will not work anymore.
Cylinder with key removed.
Cylinder with the key inserted - when the securing screw is fitted if it extends too deep then the key will not fit correctly and will not open the pannier.
Lock cylinder drilled.
Lock cylinder securing screw in place.
Tested and working.
This was all done on a spare handle lock assembly I have.
Its very easy and does not require any expensive tools to complete and takes about half an hour for each pannier, be careful drilling the holes, I used a hand held drill but this would be easier and more accurate with a drill press.
Cheers
Paul
