These posts are bringing back memories...
A very good old smith now passed away remarked that when compared to Winchesters (original WRA), Stevens did a LOT of hand fitting of parts during assembly, so much so that he considered every Stevens rifle and every part in one to be basically a one-off. And he priced accordingly when working on Stevens.
I'm not trying to put a damper on things here, just wishing those who make the attempt a lot of patience determining the tolerance ranges, and also the best of success.      

I don't know what the original hammers were made of, but 8620 seems to be the appropriate steel for this, yes? Then case harden after fitting?

I'd buy one; maybe two. I planned on laser cutting some of these myself, but I still work full time, and just couldn't get to it. 

It seems if you leave the lug area "beefy" you should be fine. You could even let your imagination run wild on how to checker the hammer spur.

Just my 2 cents.

Kinda hard to ask people to say how many they'd want until we have some idea of cost.

Phil

It really doesn't matter to me, except in an abstract way for curiosity of how many people really think this a thing that they need to do.  Most of the work is in doing the comparisons and building the model right.  That's the same regardless of how many are made.  If I'm able to reconcile dimensions to make something that should work okay, then I'll get quotes and find out if there's a threshold production quantity that makes economic sense.   

I'm doing this for amusement purposes, so if the cost is affordable, it will get done regardless of pre-committments, etc.  I'll also be able to make the file available if anybody things my cost is unreasonable and wants to pursue it themselves.

The costs as I see them are:

Unknown setup and fixturing job cost.
ground stock steel sheet cost at nominal per hammer
Cutout of individual hammers at $3 to $15 per square inch of cut, depending on process.
Postage and packaging.

The individual hammers will only have a couple of square inches of cut in them, so most of the cost will be in the setup and fixturing.

This also assumes that the hammers will be sold as a simple profile, and will require shaping, polishing, checkering, etc.  And hardening if needed.  If I take on that type of work, the cost would go way up as there's a couple hours per hammer in shaping, polishing and checkering.

First step, I'll get some consistent dimensions checked and see if it should work.

dave

Think I unnessarily implied that I was looking for "committment" to buy at this early stage when I was really interested in estimating number of self identified potential buyers.

Dave,
Thank you for your clear explanation of your position and intents.

Regards all,
Grisen

Serendipity !!!!!

Adding to this list:  I am 'Interested' in obtaining at least two "Lugged" hammers for Stevens Model 44 Actions I presently own.
I would also be interested in a version suitable for 1894 and 1915 Favorite Actions.  I know that it would be smaller than the '44' one so perhaps scaling of the File that cuts the '44' Blank would be possible?

Best Regards,
Chev. William

Thanks Brian!!

That looks like a valid method for modifying an existing hammer that is already fitted to a specific rifle.

Some quetions:
1) have you shot your rifle with this modification enough to know if the breechblock is actually exerting any force on the lug?
2) What would you estimate as time needed to make this modification, as well as tools needed.
3) Now that you have made this modification, could you provide Dave with information re dimensions of yours for comparison with his original lugged hammer?

Looking forward to understanding pros and cons of this method, as well as performance.

Thanks again,
Grisen