===== Pre-Production =====

This is information is for the pre-production process of preparing materials for the workshop kits.

  - Laser cut hull
  - Laser cut plug
  - Laser cut lock pick and key pin rings
  - Laser cut tension wrench
  - Saw metal pipe (pin Sleave)
  - Saw dowel length and indentation (for o-ring)
  - Saw and drill plug housing 

You will need to cut the following materials and documents for a single kit (if not specified otherwise).

  - **Hull**
    - 1x A3 6mm cardboard - lock_hull_1_v2-sheet.cdr - Approx. 1 min 40 sec per sheet
    - 1x A3 6mm cardboard - lock_hull_2_v2-sheet.cdr - Approx. 1 min 40 sec per sheet
  - **Plug**
    - 1x A3 3mm cardboard - lock_plug_v2-sheet.cdr - Approx. 3 min per sheet
  - **Lock Pick & Key Pin rings**
    - 1x A3 3mm Acrylic - lock_pick_v2-sheet.cdr - (This will produce shitloads of picks and rings)
  - **Tension wrench**
    - 1x A3 6mm Acrylic - lock_tension_v2-sheet.cdr - (This will produce shitloads of wrenches)
  - **Metal Pipe**
    - 1x 50mm (10mm O/D) metal pipe
  - **Key and Set Pins**
    - 3x 30cm (6mm O/D) dowel (Set pins)
    - 3x 25mm (6mm O/D) dowel (Key pins)
      - Key pins will need a slight groove (no more than 1mm deep, 1mm wide, 3-4mm from top) for the o-rings
      - Put o-ring on key pin and make sure it doesn't fit through the acrylic key pin ring (step 2 above)
  - **Plug Housing**
    - 1x 50mm (60mm O/D) postage tube
      - Drill 3x holes in the housing (use acrylic hole template) __This needs to be very straight and accurate!__


-**Material prep process**

- 25 and 30mm Pins cut to length 

{{:prototypes:img_6888.jpg?200|}}
{{:prototypes:img_6889.jpg?200|}} 

Press inside face of the saw blade against the inside surface of the 90 deg mitre box gap. Use a square to measure the desired length (in this case 25 and 30mm) Secure a block of wood as a stop. As you cut check your tolerances regularly.
 

- O-ring seating groove cut into 25mm Pin 
 
{{:prototypes:img_6890.jpg?200|}}
{{:prototypes:img_6891.jpg?200|}}

Set a hacksaw blade into a vice at about 45 deg. Set the dowel into battery drill chuck. cut your groove.   

{{:prototypes:img_6892.jpg?200|}}
{{:prototypes:img_6893.jpg?200|}}


- Plug Housing cut 

{{:prototypes:img_6908.jpg?200|}}
{{:prototypes:img_6910.jpg?200|}}

Again secure a timber stop in the mitre box measuring with a square, this time 50mm,
 
{{:prototypes:img_6909.jpg?200|}}
{{:prototypes:img_6911.jpg?200|}}
{{:prototypes:img_6912.jpg?200|}}

Clean up daggy edges on sanding belt on the bench grinder. Use the workrest on the belt sand to level up the cuts to 90 deg
 
{{:prototypes:img_6913.jpg?200|}}
{{:prototypes:img_6914.jpg?200|}}




- Plug Housing holes drilled
 
{{:prototypes:img_6894.jpg?200|}}
{{:prototypes:img_6895.jpg?200|}}

after drilling each use metal sleaves to ensure the alignment of the hole template is correct 
 
{{:prototypes:img_6897.jpg?200|}}
{{:prototypes:img_6896.jpg?200|}}
{{:prototypes:img_6899.jpg?200|}}
{{:prototypes:img_6902.jpg?200|}}
{{:prototypes:img_6904.jpg?200|}}
{{:prototypes:img_6905.jpg?200|}}

check alignment of holes on example plug are within tolerance 

{{:prototypes:img_6906.jpg?200|}}
{{:prototypes:img_6907.jpg?200|}}