How to re-key your 928: fuel cap, doors, etc.
 

One key for the hatch, two different keys for the doors, one key for the ignition and glove box , and no key at all for the fuel cap. NO MORE!!!!!!!
One key fits all.
Time consuming and the hatch lock was quite tedious, but Victory has been earned. I found the drill press and drill press vise invaluable. Be prepared to fabricate your own pins (lock pins not tumbler pins). The 928 UK site has some very useful insights into this process and is recommended reading for those wanting to do this at home.
Special thanks to Randy V.

:cheers:

Cool!

Does the fuel cap have less pins?

I got 2 extra caps when I bought the '80 car and '83 parts, a banged up metal '78 cap with key, and a plastic red cap that low and behold, my '81 key fits!! I assume the red cap came from the parts '83, but my key doesn't fit the door locks, so I'm guessing that caps must have fewer pins?

Ken, I'm willing to bet between the 3 caps, you will have no problem resetting the pins to fit your key. The 928 UK site has a write up on the petrol lock. Take the tumbler pins out of them and rearrange them to fit.
:cheers:

I did this too after the gas cap key was lost...IIRC the cap has only 3 pins (actually blades) where the doors etc have 5. I almost got there just re-arranging blades, only needed a little filing to get smooth operation. The hardest part is getting the top off the gas cap to gain access to the tumbler assembly - needs thin strong blades to hold the 'teeth' back, and about 4 hands.
jp 83 Euro S AT

www.928.org.uk

Jon in NZ

More specifically: (Community, Information Base)

http://www.928.org.uk/mambo/content/view/56/43/

This was the kit I was fortunate enough to buy from another Rennlister
http://forums.rennlist.com/upload/lockset.jpg
There are only 4 different tumbler pins used in all 928 locks. There will be 8-10 tumbler pins total in each lock. The tumbler pins are numbered 1,2,3,4
http://forums.rennlist.com/upload/tumblers.jpg
You must remove the pins from both sides of the lock. This can be done either by prying them out (very difficult) or drilling them out. I used a 3/32 drill bit and my drill press vise and drill press.
http://forums.rennlist.com/upload/removepins.jpg
When taking the lock apart, be careful as the tumbler pins are spring loaded and may come out of the tumbler. The springs may or may not come out too. A pair of hemostats worked well to remove and replace the tumbler pins and springs.
http://forums.rennlist.com/upload/tumbler1.jpg
http://forums.rennlist.com/upload/spring_copy2.jpg
The wrong pins for your key will stick out of the tumbler as shown.
http://forums.rennlist.com/upload/wrongtumblers.jpg
You will want to rearrange the tumbler pins until they are flush with the outside of the tumbler. You may also file them down if you don't have all the pins you need. Both sides must be flush when the key is inserted as shown.
http://forums.rennlist.com/upload/correcttumbler1.jpg
When you reassemble your lock, you will have to re-pin your lock. I used ordinary nails that I cut the end off flat, tapped them in (don't tap them in too far) then cut them off flush with a Dremel tool and cut off wheel.
http://forums.rennlist.com/upload/makepin.jpg
If you are really lucky you may just have to re-arrange your pins to get the key to fit. If you have an old lock or two lying around, you probably have all the pins you need. This information along with the 928 UK site info should get your door locks done. I will remove my hatch lock again and photo the take down and what needs to be removed for the hatch lock in the next post. HTH

BTW, I have a couple of extra door lock tumblers. If your lock is FUBAR and all you need is another tumbler and not the whole lock body, PM me. Free of course.