Originally Posted by corys
3. Do I need a new handle/assembly? In 30+ years someone could have changed something and we won't be able to find the right key so I may have to replace the handle or assembly. I am okay with that but how? I took out the outer screws and I do not see any other pins or connectors out there. I removed the 6 screws inside and drilled out the 2 places where it was spot welded and that let me take off the inside cover. I soaked the handle with WD40 and I cannot get anything else to come off.
A couple of years ago I ordered the outer handle (with lock) and inner latch from scamp
and it fit fine on the original inside mechanism from 1977.
The outside handle has a square shaft that you see coming through to the inside handle. The outside handle and shaft just slides into the inside mechanism BUT after all these years shaft is sort of rusted and stuck.
See scamp store picture of new outside handle with shaft.
And inside handle with hole for shaft.
What I did is best done as a two person job because you need someone to brace the door.
With someone bracing the door on either side of the outside handle use a flat bottom drift punch smaller than the shaft to tap in the center of that square shaft from the inside and drive it out. Use care to position drift punch the center of the shaft. Moderate force, start gentle but don't hit it too hard (say less than 1/2 the force of driving a nail max)
If it slides out. Cool your locking handle and latch are out. If not....
I used a small propane
torch to heat just the square shaft from the inside then applied WD40 or maybe Breakaway penetrating oil. Have to be careful to not overheat that shaft (melt fiberglass) and not allow the heat from the torch to get aimed at anything but the shaft (melt liner in a heartbeat from 2 feet away if directed at it).
Your just applying a little heat to cause shaft to expand then quenching with penetrating oil. The lubricant "follows" the retreating heat back along the shaft. Expansion and contraction helps shaft to break free.
Heat, quench with penetrating oil, brace door, tap a few times. Repeat as needed. Once it starts to move it will go pretty easily.
Locksmith can repair lock or provide matching key but new handle from Scamp is $16 and comes with key. All shiny too!
New outside handle the shaft is too long, one size fits all length intended to be cut to fit your door thickness so it ends up flush with inside handle.