Some Pelican cases come with stainless steel padlock protectors to prevent damage to the polymer due to wear from an attached padlock. However, the stamped stainless steel padlock protectors can come loose overtime. Especially in rough conditions like getting bumped around in transport. Luckily, if they do become loose with the padlocks on, they’re not going anywhere, so you can reattach them pretty easily with the method described here. This has happened to me a few times now whilst travelling abroad with these cases loaded up and with padlocks on them.

For those wondering, I use (in order of preference) Abloy PL321/PL330/PL340 typically or if I don’t have any on-hand Lockwood 120/60 or 119/50.

You can also replace them if you find a vendor that sells them as spares as you can see in the following video.

 

Tools Required

The only tool you require is some form of punch (and hammer) or an automatic centre punch. I’ve decided to use a Spring Tools centre punch (their hinge and nail set tool would work tool).

Instructions

Honestly it’s pretty straightforward (and I could have honestly done a #short - my attention span is that short yet!), but for any doubt/clarification.

1. Reinsert the loose padlock protector ensuring that it’s oriented correctly (refer to the official Pelican Case video above) as the part isn’t exactly symmetrical (the longer section faces outwards).
2. Punch the padlock protector at the locking tabs to secure the padlock protector in place (pictured below). Check for fit and re-punch if it’s still loose.

Alternatives to Padlocks

You can also get replacement latches that have low profile tubular locks on them. Colorcase sells TSA compliant ones as well (as well as some similar ones on Amazon if you search around). Luckily I don’t deal with the TSA much so I typically don’t use these. You can use the same punch tool to replace the latches. DeviantOllam covers it in this video: