These materials are per participant if not specified otherwise:

  • 1 x A3 corrugated cardboard sheet, 3mm
  • 2 x A3 corrugated cardboard sheets, 6mm
  • 1 x A3 coated acrylic 3mm (for picks, plug support chamber support 10 - per sheet)
  • 1 x A3 Coated acrylic, 6mm (for tension wrenches - 30 per sheet )
  • 1 x Postage tube, 51mm (O/D:60mm)
  • 3 x 45mm metal pipe (I/D: 7-9mm O/D: 10mm)
  • 3 x Retractable Ballpoint pen (for spring)
  • 3 x Skewers (3mm diameter)
  • 3 x 30mm Dowel (Diameter: 6mm)
  • 3 x 25mm Dowel (Diameter: 6mm)
  • 3 x O-ring (I/D: 4.1mm O/D: 7.3mm), Nitrile rubber
  • 2 x strong mini magnets
  • Electrical tape
  • 2 x Rubber bands (fit around the hull)
  • Sandpaper (not too rough)

Notes - 28 Nov 2016

Andrei and I looked out files for cutting and a hard copy protype of of the latest Lock as per Phil's instructions


We built the prototype from these parts and have got it working fairly well.

There are a couple of design files that need to be found or drawn up for:

  • the back plate of the hull
  • front Plate of the Hull (possibly with some branding- if we have time)
  • front cover for the plug (to hide the tape)

Here's the finished product without the Plug front and hull front

We'll cut one of these from scratch and assemble as a test before prepping boxes

Here's the exploded view of all parts without the three parts mentioned above

Notes - 01 Dec 2106

Found that the 3mm cardboard (which is actually 3.5mm) is too thick to cut plug parts have moved to 2.7mm pallet pad

Packing Instructions for Woodford

The Packing process has been designed to ensure the kits are presentable, parts are easy to find and in a logical order (to assist in delivery in the dark at Woodford) and can be easily check that all parts are in each kit

List of parts


6x standard hull plates 1x Front cover plate 1x back cover plate 1x Hasp plate

Plug/ barrel

7 x Key hole plates (#17 spare, 16, 12, 11, 7 & 6) 6x plug support plates (#15, 14, 13, 10, 5 & 4) 2x Plugsupport/magnet plates (#9 & 8) 1x Back plug plate 1x front plugg plate (6mm double ply card) 1x plug cylinder ( postage tube) 2x desiccant satchel

Timber parts

3x skewers cut in half (6x 1/2 skewers) 3x Top Pin (Dowel 30 mm) 3x Key Pins (Dowel 24mm with seat) 3x Orings

metal Parts

2x magnets 3x chamber 3x camber spring

Plastic parts

1x Chamber support (small holes) 2x Chambers support (regular holes) 1x Lock Pick 1x Tension Bar (6mm) 18x Plug supports 2x plug support spare


workshops/public/lock-delivery-woodford/production_notes.txt · Last modified: 2018/06/25 13:10 by Andrei Maberley
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