Apologies for not participating very much in last week's ST&C thread. We were very busy with house guests, shoots, etc.
Here's a catch-up in the longrifle work:
When I got home after shooting last Sunday, Nancy was out, so I decided to undertake the risky job to putting a brass plate on to the back of the patchbox cover. I've frankly been afraid about starting this because once you take that first file stroke, there is no going back. On one hand, I was worried about ruining the gun with this job; on the other hand, I knew I'd never be completely happy with the gun unless I did this. The other hand won out yesterday. So, please forgive the overly detailed saga of how this is done.
The first step is to dismount the latch and cut back the rear of the patchbox cover until the wood is precisely equal to the wood on the inside of the buttplate, all the while retaining the rather complex shapes of the part (impossible to see on pics).
I had a chunk of scrap brass plate. Knowing that I would be working it to precisely match the profile of the rear of the patchbox cover, I first annealed the brass by heating to a very high, temp and then allowing it to cool slowly. This makes it easier to bend and hammer into shape. As the brass became work hardened during this whole process, I had to anneal it several times to keep it co-operating but won't show this again.
It was then rough cut with a hacksaw:
Then, filed a bit closer to shape, but still allowing quite a bit of extra for fitting this tricky little part:
A lot of modern flintlock builders shortcut this process by simply using epoxy to hold the now fully shaped brass to the cover. That also has the benefit of filling up any spaces between the brass and the wood, so the wood-to-metal fit looks perfect, even if it's not. It also greatly reduces the risk of ruining a project by driving screws into very thin wood. Since I want this rifle to be period correct, I used the 1760 method of using small screws to attach the brass. Holes are drilled and then small countersinks created, because the screws are used like rivets. (Yes, I cheated with an electric drill...)
Driving screws at an angle into the very thin wood without either splitting it or coming through the bottom, requires, first, tiny screws. I never inherited money from my PA Dutch grandparents (they didn't have any), but I inherited all sorts of old cans full of screws, bolts, parts, etc. I was able to come up with two 3/8" flathead screws from this old tobacco can that had been my grandfather's.
Given that he taught me basic gunmaking skills as a child, I was pleased to be able to incorporate something from him in the rifle.
First, you drive the screws partway in to create the threads, then you cut off the tips of the screws (they would come though the bottom if left full length), then screw the stubs tightly into the threads you have created. Now, the plate is on the cover. No epoxy.
Everything is filed down to proper thickness to match the buttplate and to get rid of the screw heads, turning them into rivets.
Then the plate is filed down to the shape of the cover, leaving a tiny bit of extra, which is then slowly fitted to and blended into the curves of the buttplate, like so, until both wood-to-metal and metal-to-metal fits are good everywhere. The latch is reinstalled. Finally, you must make sure the latch works smoothly and that the cover doesn't bind.
Maybe 6 or 7 hours or work, but I was happy with the result and there were, fortunately, no rifle-wrecking mistakes. Went back upstairs to enjoy the evening with Nancy and the deer watching hounds.
Monday was lock and **** day. Again, this took quite a bit of time to get the result I wanted - no machine tool marks; a finish smooth enough for engraving, but not a modern polished finish; all while retaining the necessary flats and precise geometry of the parts to one another. Turns out, I did need to build a few special tools to fully take down the lock; which also added time to the project.
Filing up the lockplate - using the engraving vise to hold the part really helped.
Finished lockplate - ready for engraving:
Finished ****:
These parts will all be period-correct corrosive blacked after the engraving is done, which will cause the engraving to pop and give the parts a nice depth/texture.
I'm pretty happy with my carving designs now, so I've started to play around with the engraving designs. I'm not very happy with my scribbles so far. It's easy to get carried away and be too elaborate with the engraving - which was pretty simple back in the 1760's. Back to the drawing board with this....
Wednesday: Tools now resharpened from the assembly process, it's time to start the carving. I had great trepidation to start the carving. It requires a strong and steady hand; and I haven't done this in many years. One slip with a sharp tool under pressure and the whole thing is junk.
I decided to start with the easiest stuff and not get into the fancy stuff until I see if my hand and eye for this kind of work still exist. The various moldings are the easiest to do, but any tiny wiggle will show because they are supposed to be straight. So, the first scary cut of the project was the lower butt molding on the cheek side. (These pics do a really lousy job of showing this sort of work, BTW).
Since this gun will have both incise and relief carvings, the upper part of the molding needed to be relieved and smoothly blended to give me the proper shape. These shapes carry over into the buttplate.
At first, I thought this wasn't too bad, so I cut and relieved the butt molding on the lock side and started working on the three cheek piece moldings, which are done in true 1760 Berks County fashion.
My confidence began to fade for some reason, so I decided to quit carving and go do my exercise before I made an unrecoverable mistake. For me anyway, patience is the key - there is no hurry.
Thursday, I finished up the cheekpiece moldings; cut incised lines on the forestock and put the muzzle end finial on them. Cutting such long lines absolutely straight by hand with a chisel is tricky and takes a good bit of time - any tiny wobble shows up; one slip and you damage the very thin wood there. For some reason, the pics of this kind of work don't show it well at all. Sorry.
Now, that line will need to be relieved along its length, by very smoothly carving away wood above it, so the molding sticks out. That is a Berks County feature. Also, hard to do well as any flaw will show.
Friday, I only had a little time because we had friends staying at our house to attend a Ruffed Grouse Society fundraiser shoot in Lancaster on Saturday and a sporting clays competition at my club on Sunday. So, I did only a few hours of work roughing out the relief carvings on the front of the comb area of the rifle - again in the distinctive Bers County stye:
Each day there were the usual dog runs. Joy and Bliss by one of the mountain lakes:
Yet another wild goose chase by Joy in the icy waters:
Bliss in action:
They found some big, but very wary wild turkeys:
Greg
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