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.
(http://highett.smugmug.com/Other/Pannier-Lock-Assembly/i-3zRZdvR/0/L/P3170050-L.jpg)
From inside undo the screws and it comes out easily.
(http://highett.smugmug.com/Other/Pannier-Lock-Assembly/i-J4hNc6p/0/L/P3170054-L.jpg)
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.
(http://highett.smugmug.com/Motorcycles/Pannier-Lock-Tumbler-Removal/i-SPhDFkJ/0/L/Tumbler%20and%20Removal%20Tool-L.jpg)
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.
(http://highett.smugmug.com/Motorcycles/Pannier-Lock-Tumbler-Removal/i-6MQbskC/0/L/Pannier%20Lock%20Tumbler%20Removal-L.jpg) (http://highett.smugmug.com/Motorcycles/Pannier-Lock-Tumbler-Removal/28791259_hM9p54#!i=2444333962&k=6MQbskC&lb=1&s=A)
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.
(http://highett.smugmug.com/Motorcycles/Secduring-the-lock-cyclinder/i-txzFwp9/0/L/P4140182-L.jpg)
(http://highett.smugmug.com/Motorcycles/Secduring-the-lock-cyclinder/i-QH3q9Df/0/L/P4140184-L.jpg)
Enlarge the hole in the backing plate to accept the screw head - be careful not to drill into the plastic underneath.
(http://highett.smugmug.com/Motorcycles/Secduring-the-lock-cyclinder/i-x2758hX/0/L/P4140188-L.jpg)
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.
(http://highett.smugmug.com/Motorcycles/Secduring-the-lock-cyclinder/i-zj9wzrq/0/L/P4140189-L.jpg)
Cylinder with key removed.
(http://highett.smugmug.com/Motorcycles/Secduring-the-lock-cyclinder/i-7HKkcbT/0/L/P4140190-L.jpg)
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.
(http://highett.smugmug.com/Motorcycles/Secduring-the-lock-cyclinder/i-VvM2qsM/0/L/P4140191-L.jpg)
Lock cylinder drilled.
(http://highett.smugmug.com/Motorcycles/Secduring-the-lock-cyclinder/i-LW89ztg/0/L/P4140193-L.jpg)
Lock cylinder securing screw in place.
(http://highett.smugmug.com/Motorcycles/Secduring-the-lock-cyclinder/i-XmWJxtM/0/L/P4140194-L.jpg)
Tested and working.
(http://highett.smugmug.com/Motorcycles/Secduring-the-lock-cyclinder/i-9s8sSvF/0/L/P4140195-L.jpg)
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