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Slow progress on my .40 build.

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1BadDart

45 Cal.
Joined
Dec 26, 2021
Messages
703
Reaction score
958
Location
W. KY.
Finally starting to make a little progress on my .40 build. After a mix up on the hardware and inletting on my stock my parts are finally here. I had to add some epoxy because the barrel inletting was very deep at the breech end.

The lock inletting required a little work, this rifle will be shot with a cap and a flintlock. The locks are large Silers and there are differences in the size of the lock plates and one doesn't fit as tight in the inlet in the stock. The bolster on the flintlock was ground on a angle, wider in the rear than the front. The stock had a similar taper in the lock area so I assume it was supposed to be that way. The problem was the percussion's bolster was ground straight from the front to the back. This wouldn't be a issue if the rifle was using only the flintlock or the cap lock. Since I'm using both I filed the percussion's bolster to the same dimensions of the cap lock's bolster. Once the locks were fitted I had to use a hand plane on the stock around the locks. Once that was finished I planed the plate side to match the lock side.

I didn't like the side plate that was in the hardware, it looked like a butter knife with a round lobe on top. So, I sat down with some heavy paper and started drawing, after several attempts I came up with something that appealed to me.

There is still a lot of work to do, the butt plate and trigger guard need finishing, the trigger has to be inletted, then drilled and tapped for the tang screw, the stock has to be cut for LOP and the butt plate fitted. The dovetail cutter should be here today to make the cuts for the barrel lugs, then the inletting and pins installed. The barrel is 42" and will most likely be cut to 38-39", then the nose cap and thimbles installed and finally the stock has to be finished.

After typing all this I'm just getting started. LOL

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It's looking nice. I love my Dremel - so many uses for it with the various bits and attachments you can get. It's also my go-to for cleaning hard-to-reach areas of rust on metal parts (using one of the various wire brushes they make).
 
The rifle is slowly coming along. The trigger inletting is done and the tang screws are in. Today I dovetailed the barrel for the lugs, fitted and installed the lugs and inletted the stock for the lug.

To say I've been a little apprehensive about these steps would be an understatement. Having never done any of this before I'm just fumbling my way through it.

Barrel set up i my little mill for the dovetails.
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The barrel is pinned, just need to elongate the holes in the lugs. Next is the trigger guard, then cut the stock and install the butt plate.

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I bought the old horizontal mill a couple years ago, wasn't really sure what I'd use it for. It's been pretty handy and has simplified several parts of this build.
 
The thimbles and entry pipe are in and pinned, not perfect, but good enough for who it's for. :)
I'll tackle the butt plate today.

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The wife and I are back from vacation in the Smokey Mountains, it was a great trip with good weather. Unfortunately, we both brought back of covid with us, back Thursday, in the doctors off Friday.

I have been tinkering with the rifle and wasted the biggest part of yesterday afternoon making a front sight on the mill I can't use. I'm using an adjustable rear sight off a Thompson of some sort with a round barrel. A few cuts were made to the base of it to make it fit my octagon barrel. Also made a toe plate and finished fitting the butt and toe plate. They came out okay, but the shape of the stock keeps things from looking symmetrical. Maybe I'll do better if I build another one.

The barrel is drilled and tapped for the drum and liner, It didn't come out exactly square with the barrel but certainly workable. Lesson learned, always check the set up in the mill even you haven't changed anything since it was last used. Also I had to file a small notch in the breech plug, just enough to clear the threads o the drum/liner.

This has been a learning experience and when I get this rifle finished, I'm thinking the list of what not do's will be longer than the to do
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list.
 
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