Flintlock Question

Interesting comments Erwan and welcome & good morning Ezekiel. There is allways more than one way to skin a cockroach . And we learn stuff every day. All these interesting comments are at the heart of flintlock shooting . Got to have sparks ! . Reminds me of an observation a barrel maker made "Rich people and poor people both have ice , Only difference is rich people have it in the summer time ". Which HAS to be a very old joke , Might have been Jerry Cunningham a very philosophic Gentleman..
Regards Rudyard

Good morning to you too Rudyard. your joke reminds me of the Tommy cooper one:
Vet holding dog: lady you dogs got to be put down.
Lady: But why? hes only got a scratch on his leg
vet: hes too heavy
Sorry

I like EZEIKEL'S (Post19) approach.Sounds good. Do you use MIG, Plasma or Laser??
I'm lucky I have access to all three.
OLD DOG..

What I normally tack weld the blade in place with arc or mig and get the angles correct and when Im satisfiedV out the bottom surface and weld with mig then repeat with the top. clean it all up and re harden the blade concentrating the heat on the working face and quenching in water.
I have had them tig welded with nickel based rods but the joint shows. Seems to be no issues with different metals or stress problems. I think the oldest one Ive done is about ten years ago.

My Lyman Great Plains flintlock was having trouble with not sparking back when I was shooting in monthly shoots in 2001. I was told that the frizzen was only surface hardened and I'd worn through that. The other shooters recommended having a shop in Fairmont, WV weld on a piece of saw blade. I sent it to the shop and for $25 he did that, mailed it back to me and gave me a few flints. I've not had any problems with sparking since then.