Thankfully with a little creativity, some fancy welding work, and a pretty good sense of humor, the modified, uber, epic, mega lock was born!
Step 1: Things You're Gonna Need
- U Lock (we used an Onguard Bulldog 5006 Pitbulll Mini Series Lock- retailed $45)
- MIG Welder**
- Cut Off Wheel
- Angle Grinder (24 grit grinding disc)
- Two metal rods cut to desired length. We used hardened steel at 40" in length; long enough to lock up 4 bikes. (be sure that the diameter of the rods are the same or close to that of the original lock)
- Vice Grips
- Plastic accordion tubing
- Spray Paint
**If you don't own a MIG Welder (gasp!) and live in the SF Bay Area, near Detroit, MI, or Raleigh, NC, don't fret. You can use the welder at the Tech Shop! ***
Step 2: Cutting the Lock
Remove bottom piece (the lock) so that you are working on the original U rod of the lock, and take off any protective rubber that might be on it.
On each side, make a cut just above the locking ends of the rod, and just below the curve of the top of the rod, basically somewhere in the middle
Measure at equal points and mark where you will cut.
Using a cutting wheel, cut through the markings on the rod. Originally I tried using a band saw, but it wouldn't cut because the rods were made of hardened steel, which means it resists traditional cutting.
Step 3: Grind Off Edges
Grind all ends of rods that will be welded (original and new steel)
Before welding, use a straight edge (in this case, we used a piece of angle iron as seen in the photo) to make sure the parts to be welded are properly aligned.
Step 4: Weld Baby, WELD! (the Top Edition)
FIRST WELD: Once you have aligned the long rod to the original curved end (with the help of a straight edge), tack weld the two pieces together, so that when you go to make the final welds, the pieces won't move or shift.
SECOND WELD: Line up the long rod as you did with the first rod that you just welded. Measure the two floating ends BEFORE you tack to be sure that they are are the same distance apart as they are at the top. Essentially, you are making sure before you weld, the two long pieces are not bowed in or out. Keep it symmetrical baby!
Step 5: Weld Baby, WELD! (The Locking Bits Edition)
Lock each machined end (the stock ends of that you originally cut off) into the lock and lock them in place with the key. This ensures that when you weld the giant rod use to the machined ends, everything will be aligned.
Holding the base in place with vice grips, tack weld the long U rod to the machined ends (still attached to the lock base)
Once tacked, remove the lock (and for good measure, re-lock to make sure the locking mechanism still functions before you weld).
If all is good, remove the locking base (so the heat doesn't destroy it) and finish welding.
Step 6: Finishing Up the Metal Work
Now step back, light up a cigar, because you just created an uber, epic, mega lock!
Step 7: Finishing Touches- Protect Your Investments
For this, we made one long cut down the length of the tubing so we could slide it over the metal rod.