Snapped ignition key for Evinrude power pilot control box

[Pongrasslover]

Hi All,
I have recently bought a 74 Pongrass Surfmaster with a 50hp power pilot control up front that has snapped an ignition key & the key cutting provider in town says they can't replicate one without removing the ignition barrel & casting one from it (even though I have both pieces). Does anyone know how to get the power pilot control box apart to remove the key cylinder? I started to have a crack at it tonight but realised it would be best to get some guidance first. Alternatively has anyone had a similar experience but successfully had the key recut? I ask only to see whether the Key Services response was justified or whether I should try another company outside of Gladstone.

 

[Silvertip]

Re: Snapped ignition key for Evinrude power pilot control box

You don't have to disassemble anything. Most hardware stores or stores like Harbor Freight, Northern Tool etc., sell used dental tools. Use a dental pick to extract the remainder of the key. Now that you have both pieces, super glue or epoxy the two pieces together as tightly as possible. The Johnson/Evinrude key is a very standard Briggs & Stratton style blank. Any place that does keys can provide you with the blank. Buy a couple (reason will follow). By a couple of small files. These can usually be found in a set of three or four and range from round to flat to tapered to triangular. Place the broken key over the new blank key and scribe the pattern using one of the dental picks. Patience will now be required as you very carefully file the the new key. You will very likely screw up the first one since you are not a great "filer" at this point but you should have success on the second attempt. Remember, the distance from the shank of the key to the tip must match otherwise all of the peaks and valleys on the key will be wrong. Once you have a key that works, take it to a key shop and have a couple made. But the really quick way to do this is to check the code letter on the key and take that to the Johnson/Evinrude dealer parts dept. There are not many keys and they are not expensive. With your epoxied key you can even match up the key on their "try-out ring".

 

[Pongrasslover]

Re: Snapped ignition key for Evinrude power pilot control box

Thanks Supreme Mariner,
Yep as soon as I snapped it (after a few choice words) I said to myself " well this time I'll get 2 done". As you suggested I'm definitely not a great filer but I really appreciate the advice you've given & will take up the challenge of prepping a new key with this method.

I wasn't keen to be pulling apart the control box to pull out the key barrel for a locksmith to rekey (the suggested solution given to me by a local locksmith) especially when I'm a boating novice so this is a far better option.

Cheers mate.....