Cycling Equipment · Public discussion

U-lock hollow shackle?

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7 July 2005
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  1. As many U-locks are attacked by bolt cutters, I was wondering about how
    they (the locks) have their shackle made. Does anyone know if
    manufacturers have tried to make extra-large diameter shackles (1 in=25
    mm or greater) to make it so that bolt cutter jaws cannot fit around
    them? Now b/f people say that that's insane in terms of weight and
    cost, here's my idea. One can have in theory a large diameter shackle
    that's hollow. For an equivalent weight of steel, a hollow shackle
    would have a greater diameter. It seems to me that as long as the
    shackle were strong enough to resist crushing (here a circular cross
    section is best), it would be superior to the thin solid shackles. I
    wonder if I'm missing something, say in manufacturing difficulties or
    something else.

    Later,
    Nelson Chen
    __o Same road Boycott Wal-Mart, union-buster.
    _`\<,_ Same rights
    (_)/ (_) Same rules

  2. Quoted message said:

    As many U-locks are attacked by bolt cutters, I was wondering about how
    they (the locks) have their shackle made. Does anyone know if
    manufacturers have tried to make extra-large diameter shackles (1 in=25
    mm or greater) to make it so that bolt cutter jaws cannot fit around
    them? Now b/f people say that that's insane in terms of weight and
    cost, here's my idea. One can have in theory a large diameter shackle
    that's hollow. For an equivalent weight of steel, a hollow shackle
    would have a greater diameter. It seems to me that as long as the
    shackle were strong enough to resist crushing (here a circular cross
    section is best), it would be superior to the thin solid shackles. I
    wonder if I'm missing something, say in manufacturing difficulties or
    something else.

    AFAIK most of them are actually broken with a car jack. Power tools are
    becoming more popular with the advent of good rechargeable disc cutters.
    And then there's the trusty Bic pen ;-)

  3. Quoted message said:

    As many U-locks are attacked by bolt cutters, I was wondering about how
    they (the locks) have their shackle made. Does anyone know if
    manufacturers have tried to make extra-large diameter shackles (1 in=25
    mm or greater) to make it so that bolt cutter jaws cannot fit around
    them? Now b/f people say that that's insane in terms of weight and
    cost, here's my idea. One can have in theory a large diameter shackle
    that's hollow. For an equivalent weight of steel, a hollow shackle
    would have a greater diameter. It seems to me that as long as the
    shackle were strong enough to resist crushing (here a circular cross
    section is best), it would be superior to the thin solid shackles. I
    wonder if I'm missing something, say in manufacturing difficulties or
    something else.

    I expect that it is manufacturing issues that keep such a lock off the
    market. While it's not exactly difficult to make a tightly bent
    thick-walled tube, the economics of producing things for the mass
    consumer market make everything other than the cheapest methods
    uncompetitive.

    I see a lot of merit in your idea, but it would be difficult to make
    the weight similar to a normal u-lock without the shackle being
    vulnerable to crushing (note that crushing the shackle would not
    necessarily make it easier to cut or remove the lock by force).

    A 12.7mm solid rod weighs the same as a 25mm tube with a 1.74mm wall
    thickness. That's only about twice as thick as an inexpensive bike's
    tubing. So it would have to be made of some tough stuff to resist easy
    cutting once flattened.

    Tubing is expensive compared to rod, and tubing made out of very tough,
    high-tensile material is _really_ expensive compared to rod. I imagine
    that it would be more cost effective to use a rod of a stronger,
    tougher alloy than it would be to make a tubular shackle. Because even
    though lock manufacturers love to boast about how strong their shackles
    are, the metals used are not that remarkable.

    If somebody saw fit to make a lock with a shackle of Carpenter Aermet
    100 or Inconel 718, now that would provide some pretty good security.
    Best not lose your key, though.

    Chalo Colina

  4. Thank you for your informative reply. It really was an eye opener how
    you showed how the 12.7 mm solid rod has the same amount of material as
    a 25 mm tube that's only 1.74 mm thick. I even checked the math myself
    :-). Might be better against bolt cutters, but very vulnerable to
    crushing attacks. Also, I'm glad you pointed out that hollow tubing is
    really expensive compared to the solid rod.

    In terms of economics, I believe that there is always the question of
    demand. If I'm not mistaken, the makers of today's top locks (Abus,
    Kryptonite, Onguard, etc.) mark up their top designs a lot. I just saw
    the New York 3000 for sale today at a LBS for $80. People willing to
    pay that much for those locks probably will pay top dollar for
    something *truly* shown superior. How much of the cost is really the
    material cost, and how much is the locking mechanism and fabrication
    cost? Thought just dawned on me how concrete is very good against
    crushing. How about a concrete filled shackle? Wait, that would be very
    heavy though.

    This thread is making me wonder if we should have a discussion on the
    *physics* of bolt cutters and cutting - some initial thought convinced
    me that it's much more complex than at first sight - issues of
    sharpness, pressure, compressive strength, buckling, etc. just to list
    a few.

    Later,
    Nelson Chen

    __o Same road Boycott Wal-Mart, union-buster.
    _`\<,_ Same rights
    (_)/ (_) Same rules

    Chalo said:

    I expect that it is manufacturing issues that keep such a lock off the
    market. While it's not exactly difficult to make a tightly bent
    thick-walled tube, the economics of producing things for the mass
    consumer market make everything other than the cheapest methods
    uncompetitive.

    I see a lot of merit in your idea, but it would be difficult to make
    the weight similar to a normal u-lock without the shackle being
    vulnerable to crushing (note that crushing the shackle would not
    necessarily make it easier to cut or remove the lock by force).

    A 12.7mm solid rod weighs the same as a 25mm tube with a 1.74mm wall
    thickness. That's only about twice as thick as an inexpensive bike's
    tubing. So it would have to be made of some tough stuff to resist easy
    cutting once flattened.

    Tubing is expensive compared to rod, and tubing made out of very tough,
    high-tensile material is _really_ expensive compared to rod. I imagine
    that it would be more cost effective to use a rod of a stronger,
    tougher alloy than it would be to make a tubular shackle. Because even
    though lock manufacturers love to boast about how strong their shackles
    are, the metals used are not that remarkable.

    If somebody saw fit to make a lock with a shackle of Carpenter Aermet
    100 or Inconel 718, now that would provide some pretty good security.
    Best not lose your key, though.

    Chalo Colina

  5. Zog The Undeniable said:

    AFAIK most of them are actually broken with a car jack. Power tools are
    becoming more popular with the advent of good rechargeable disc cutters.
    And then there's the trusty Bic pen ;-)

    Does anyone have any statistics on how common it is to have a U-lock
    broken? The reason I ask is because I've had terrible luck with bike
    theft, but have never had a U-locked bike stolen. Over the past 8
    years, I've had a bike w/a cable lock stolen, two unlocked bikes
    stolen, and the wheels stolen off a bike whose frame was U-locked. The
    U-lock I've used was a low-end Kryptonite for a while, normal size,
    which I got replaced with a similar flat-key model.

    My main worry isn't usually whether my frame is going to walk away in
    downtown DC, I worry about vandalism and theft of small parts. By the
    time I lock down my front wheel, seatpost, remove lights, bags, and
    computer... my good commuter road bike is not much fun to deal with
    anymore. So I only take the beater when I'm going to leave it outside
    unattended for more than 1/2 hour.

    Has anyone tried these locking skewers?
    http://www.veratomic.com/phpshop/frame.php?p=1 They appear to be a
    good deal.

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