Abstract: A method for variably making tie bar guides usable to guide tie bars within locking system housings having different inner dimensions, which tie bar guides have a body portion including four sides substantially aligned with an opening through the body portion for slidably receiving a tie bar. A mold block defines an opening for the body portion of the guide and receives material in a substantially flowable state. A cylindrical channel is also provided in the mold block along one side of said body portion opening. A semi-cylindrical pin is secured within the channel, which pin is pivoted to open a selected portion of the channel to the mold block opening and thereby extend the mold block opening and contiguous open channel to a selected outer dimension. Further, at least one slot is provided along a second side of the body portion opening.