Replacing KT Lock on 75 Overlander

[dbj216]

KT locks wear out and vital parts fall off. I have one on my 75 Overlander but have decided to replace it with a modern RV lock. This thread will show the steps in my KT lock replacement project.

We all know a rebuilt or replacement KT lock is quite expensive. I just figured there must be a better alternative. And I discovered there is.

I purchased a Korhee RV lock for about $50. It is a high quality piece and more robust than the KT lock. The Korhee lock has a built in door pull on the inside. I think pulling the door shut with the KT lock lever is one reason the KT locks have trouble. The Korhee lock comes with a built in deadbolt. Another advantage for me.

So here we go.

David

[dbj216]

I want to add that my wife's 86 Limited 34' had its original door lock replaced with a Korhee lock maybe 25 years ago. Her father did the job and I can remember him saying it was somewhat challenging. That lock is still going strong. Here is a photo:

The reason for this project was my son's 69 Globe Trotter. It had a Bargman L-200 which I overhauled back in 2016 but it was just plain worn out. The KT lock on my 75 Overlander was working good. So I removed the KT from the Overlander and installed it in the Globe Trotter. Airstream started using KT locks in 1970 I believe, so my son's 69 looks like a 70s trailer now.

I needed a new lock for my Overlander. I hoped I could make a Korhee RV lock work

David

[dbj216]

Here is a photo or two of the KT lock on the 69 Globe Trotter. Looks quite vintage there. I had quite a bit of modifications to do. The first thing was to insure I had enough lock bolt length to reach through the cast door frame on the 69.

David

[dbj216]

The KT lock wqs long. The Overlander door frame is cold formed aluminum, not a cast frame. This allows the use of a shorter lock bolt set back. There is a door cross member that the Korhee lock had to sit on. So I had to make a new hole for the lock bolt in the vertical door frame member.

I also had to shim out the new lock bolt receiving hole in the vertical door jam. to get good lockbolt engagement. I got it to all line up.

David

[dbj216]

I had some trimming to do to the door aluminum skins to get the Korhee lock to fit. It wasn't too bad to do. The whole installation is based on where the lock bolt penetrates the door frame and penetrates the lock bolt receiver hole in the door jam.

Here is a trial fitting. At this point I was pretty confident I could make this new lock work.

David

[dbj216]

Now it was time to make patches to cover the KT lock hole in the door skins, both inside and out. I used a piece of Alclad aluminum I had laying around. I had to cut square clearance holes for the Korhee lock set, both the outside and inside patches. I used my jig saw with a fine metal cutting blade which worked pretty good.

The Korhee lock is held tight by 4 screws inserted from the inside. This draws the lock set tight to the exterior skins. It also has two screws on the top and bottom of the lock bolt holding the lock tight to the door frame. I used the inside piece of the Korhee lock as a template for the mounting holes with the reference the inside deadbolt red lock lever.

It was a challenge to get the patches and lock all aligned and assembled using the for screws, but I got it done after some cussing under my breath.

Then I had to match rivet patterns and seal and secure the patches.

David

[dbj216]

The KT lock replacement project is done. The Korhee lockset seems to work well, both inside and out. I like the built in dead bolt, and I like that one key operates both the lever lock as well as the deadbolt lock. I believe this lock will last a very long time.

It is a lot of work to replace the KT lock, but it saves a lot of expense and results in a stronger, more reliable lock for the trailer.

There is no need to fret about rebuilding or replacing a KT lock which is no longer manufactured, unless you are restoring your vintage trailer to original factory specs. I use my Overlander and need the comfort of knowing I'm not going to get locked out, or locked in my trailer with a defective KT lock.

David

[steve46]

David, thanks for the idea and explanation with photos. This is a great idea and one I want to do for my ‘76 Trade Wind. I dislike the original lock for multiple reasons—it seems a bit flimsy, perhaps because it is getting old (like me); it has no inside “pull”, it has no inside locking provision; it has no deadbolt. To ensure the door does not fly open during travel, I use a “wedge” through the grab handle as my insurance.
I had the lock version you installed here on a previous Airstream, a ‘93 Excella, and while I did have to make a repair, it was sturdy and worked well. Your solution will solve most, if not all, of my objections to the current, original lock. Thanks, again.

[heslinhotel]

dbj216, I have replaced 3 KT locks on 3 70's trailers over the years. Never had a problem they are very robust and the inside handle is great.

Nice install.

Steve

[cole3444]

What are you going to do with your old lock. PM me if you want to sell it.

[Wazbro]

Originally Posted by cole3444

What are you going to do with your old lock. PM me if you want to sell it.

Well he he said he put his KT lock on his son's trailer.
Or did you mean the Bargman L-200 he replaced on his son's trailer and said was worn out?

[cole3444]

Well I guess he did didn't he.

[dbj216]

Hello KT lock friends: Thanks for your kind words. I did sell the old Bargman lock for parts. They are too valuable to just throw away. Folks like cole3444 and montana blue and others make a hobby of overhauling these old lock sets for the vintage Airstream crowd. It is a worthwhile hobby. I find old lock set interesting to tear apart and see how they work and guess on how they were made way back when.

The old Overlander KT lock is on the son's 69 Globe Trotter. He'll probably be mad at me when that KT lock fails and he is locked in the trailer. Dad, why didn't you just install a Kohree lock like the Overlander has? Maybe someday I will.

David

[steve46]

Thanks to the patient tutelage of David who answered all of my what must have seemed like incessant questions AND offered ideas that I hadn’t considered, I now have my new Kohree lock installed. Yes, it was a daunting task/project, yet doable by one who does not consider himself a “metal worker” at all. True confession—I have had this new lock for nearly four years but just recently found the gumption to tackle the job. I only have to finish off the exterior Olympic rivets and make some small modification to the screen door so it clears the new lock properly. I never liked the original KT lock for reasons stated in an earlier above comment and am pleased with the functionality of the new lock. Thanks, again, David!

[dbj216]

Nice work on a rather difficult job. Now you won't have to worry about an unexpected KT lock failure while on the road. My Kohee lock has worked just fine and a much better price than a rebuilt KT.

David