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Rebuilding the Manifoil Mk4 Combination Lock

Here I explain how to put the Manifoil Mk4 Combination lock back together. It is mostly just a matter of remembering the order of parts. There is nothing difficult here.

Incidentally...what a wheel looks like (a) full view, (b) locked, (c) unlocked and ready for combination changing. An S&G6730 change key has the right dimensions to unlock the wheels, but I haven't tested one to see if it will fit when the back is on the lock.

(a) manifoil assembly

(b) manifoil assembly

(c) manifoil assembly



To rebuild the lock from its parts you must start with the base:

manifoil assembly



The first two parts in order they will be put down (from right to left). They are the base washer and the first wheel. The wheel goes down with the internal rim part pointing upwards

manifoil assembly



The next three parts to be put down (from right to left): copper washer, fly, copper washer, second wheel

manifoil assembly




So far (before the second wheel is put down)

manifoil assembly



The next three parts to be put down (from right to left): copper washer, fly, copper washer, third wheel

manifoil assembly



Just before the third wheel is put down.

manifoil assembly



After the third wheel is put down. If it looks like there are 4 wheels down, it is because of the reflection in the base.

manifoil assembly



The next four parts to be put down (from right to left): copper washer, fly, clip, first cam. The clip/Circlip just needs a firm push with a screwdriver or similar to slide into place.

manifoil assembly



Those parts in place except for the first cam:

manifoil assembly



The first cam in position:

manifoil assembly



The wheel cover in place. It justs slips on if the gates are aligned and pointing away from the bar that the cover fits around. Otherwise it doesn't fit on easily. When the lock is put onto the door the bolts hold the wheel cover against the base. Until then, it sits loosely over the wheels.

manifoil assembly



The next four parts to be put down (from right to left): copper washer, copper washer, fly, clip. This fly sits with the protusion pointing downwards.

manifoil assembly



These parts in place:

manifoil assembly



The next parts to be put in position are the second cam (not pictured - I forgot...) and the two rollers. The springs on the rollers aren't too strong to be put in place with fingers (and/or a screwdriver), although they may fly off if you aren't careful. They fit as can be seen in the finished lock picture further down.

manifoil assembly



This picture shows the remaining parts to complete the lock (before it is fixed to the door). Clockwise from top left there are: the lever (lacking its fence), the lead side-shield (to prevent x-rays from the side of the wheel pack showing where the gates are), the screw-threaded bolt that holds the lever in the lock's (sliding) bolt, and the (sliding rectangular) bolt itself: (I'm trying to distinguish between the two definitions of bolt)

manifoil assembly



The lead side-shield just slides into position. It may have originally been held in place with double sided tape. For this lock, the lock's cover is the only thing that will keep the side-shield from falling off, but it stays in place ok. To fit the lever, slide the (lock's rectangular sliding) bolt (with the tiny hole on top) into its locked position. Fit the lever into it, with the lever end of the spring in the tiny hole. Put in the screw-threaded bolt to fix the lever in place.

The finished lock:

manifoil assembly



Side view:

manifoil assembly



Here the lock is shown fitted to the door, with the spline key only inserted half way (so I can take it out easily). Note how the wheelpack cover is now fixed in place with the same bolts that hold the lock to the door. Although the lever is sitting in the drive cam, the gates didn't have to be aligned in this particular case because this lock is missing its fence.

manifoil assembly



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