On Fri, 25 Nov 2011 19:33:21 -0600, "ChairMan" nospam@nospam wrote:

I've got a padlock that's been outside too long. The key won't turn
(although after copious amounts of WD40 it does, finally, enter the
lock) and it's in a rather hard to reach spot. I'm heading off to
Harbor Freight this weekend, so I was thinking that the best way to
remove the lock would be to buy an angle grinder and the appropriate
cutoff wheels.

Of course, it would be nicest to simply unlock it, and any tips or
suggestions about how to coax it open are welcome. Brass body, looks
like chrome steel hasp and brass key. Have not tried penetrating
oil, hammer bopping, vibrating, heating or cooling yet. Saving the
lock is unimportant so cutting is a good alternative as I've wanted
an angle grinder/cutoff tool for a while. (-:

I see them cutting through industrial-sized padlocks like butter on
"Storage Wars" and it looks like they are using an electrically
powered 5 or 6" angle grinder. HF sells an air powered version, but
I've got a cheap
compressor )-: that I doubt would power it. An electric tool would
be
better. I have a lithium-ion powered Dremel, but I don't think it
would cut through on a single charge. It's just to lightweight a
tool for this job.

Anyone have any tips for weatherproofing a replacement? Blobs of
silcone over the key hole and where the hasps enter the body of the
lock?

--
Bobby G.

get a set of bolt cutters and be done in about 15 seconds.
as far as maintentence, spray regularly with WD-40.
I've had some outside for over 20 years

A cheap padlock will yeild to a bolt cutter. A good one will just
laugh at it.
A good padlock will stand up to weather even without WD40 - while many
cheap ones would need to be bathed in the stuff to last a year
outside.
Buy a good rustproof padlock with a hardened shank and a weather cover
to replace it. A shot of "lock ease" every once in a while to keep the
innards working freely makes it a lot less hassle. A whole lot better
for any lock than WD40. It is a colloidal graphite concoction made
specifically for that purpose.