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Very Hot Topic (More than 25 Replies) Ballard stock adaptation/inletting/fitting (Read 10081 times)
ssdave
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Re: Ballard stock adaptation/inletting/fitting
Reply #60 - Jan 29th, 2023 at 4:58pm
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Been too lazy to mix up some acraglas and glue the escutcheon, took the time to do a final sanding and glue it up today.  First, waxed the barrel so it wouldn't be permanently attached.  Coated the inside of the forend very thinly with epoxy so it will be sealed.  Coated the escutcheon, and the inside of the recess for it, and installed the screw just tight enough to seat the escutcheon below the surface a tiny bit.  it will now sand in place with the rest of the stock finishing.  Final step, coated the entire forend thinly with the epoxy to seal the pores and match the buttstock.  Now, a couple days of drying before I can sand the epoxy off and see how it will look.

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ssdave
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Re: Ballard stock adaptation/inletting/fitting
Reply #61 - Jan 29th, 2023 at 11:20pm
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Got impatient, instead of waiting a couple of days for the forearm to dry, sanding it, and doing both at once, I put a coat of finish oil on the buttstock.  So, can see how it will look in a couple of weeks to a month, after a few finish coats are applied.

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MrTipUp
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Re: Ballard stock adaptation/inletting/fitting
Reply #62 - Jan 30th, 2023 at 8:01am
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An Allen head forearm screw?  On a Ballard?  Very, very nice and well-fitted wood though!

Bill Lawrence
  
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rkba2nd
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Re: Ballard stock adaptation/inletting/fitting
Reply #63 - Jan 30th, 2023 at 2:13pm
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Perhaps not the finished product? For constant on off applications, as in stockmaking, allen heads can be a blessing in disguise.
  

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ssdave
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Re: Ballard stock adaptation/inletting/fitting
Reply #64 - Feb 25th, 2023 at 3:57pm
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While waiting for the stock to dry enough to go on with it, pulled an old and neglected project out of the safe to work on.  Needed a forearm made, so milled a matching piece of wood to octagon, and started in.  Different style on this forearm.   

Here I start laying out the cutlines, and rasping to shape:

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Lay out some cut lines to get the taper at the front of the forend right;

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For the purists that objected to a hex head foreend screw, used a more traditional one:

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I'm happy with the forend, now go on to final fitting the buttstock before epoxy bedding everything.

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ssdave
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Re: Ballard stock adaptation/inletting/fitting
Reply #65 - Feb 25th, 2023 at 4:05pm
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Fitted the buttplate the last bit by filing it to fit, and then sanding the stock and plate together.  Didn't take pictures of the action, but sand it to fit also.

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Mixed up epoxy to bed in the foreend, glued in the escutcheon and then filled the pores on both the stock and forend with epoxy also.

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ssdave
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Re: Ballard stock adaptation/inletting/fitting
Reply #66 - Feb 25th, 2023 at 4:17pm
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Waiting on finish to dry again, so this morning pulled out another old project.  Had an unfinished action on a rifle my wife used as is, and it was stolen.  When it was recovered, it had been hidden under the floor of a shed, in the dirt, with boards thrown over it.  Need to clean it up, re-sand and finish the stock, and finish the rifle.  I decided to finish the action first, and then re-fit the stock and refinish it.

The action was parted together from a badly buffed and blued project, and I used a different tang to get rid of the crudely shaped pistol grip.  The tang didn't fit the action cleanly, and the action had grind marks all over it.  I had started working them out, but still a lot of work left.  The top and bottom tangs had gouges and unevenness, they had been ground on quite a bit, the bottom one may have been welded on.  Had to file them to shape. 2 hours with 180 grit, and a file and it looks good; ready to go to 220 and then 340 and then 400; then to Allen Springer for color case.

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Here's the scratching on it before I started cleaning it up:

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Here's filing the bottom and sides till the bottom tang matches the receiver:

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Reminds me that I'm a lot more of metalsmith than a woodworker, much easier to do and make it look right!

Final rough fit back on the wood to make sure it still fits; now to sand and refinish the wood.  

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Re: Ballard stock adaptation/inletting/fitting
Reply #67 - Feb 25th, 2023 at 5:01pm
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Very good work and you’re being very productive. Keep up the good work.
  
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marlinguy
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Re: Ballard stock adaptation/inletting/fitting
Reply #68 - Feb 25th, 2023 at 5:50pm
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Nicely done Dave! A very classic designed stock!
Just finished a similar project here Dave. A Remington Rolling Block conversion from military to Sporter that I purchased last fall. It had a military buttstock still, and a sort of varminter style forearm. The barrel is a heavy #4.5 or #5 weight BW Darr in .35-40 
I converted it with a pistol grip lower tang, and then fitted an original Rolling Block Sporting forearm I had. Got a pistol grip semi inletted buttstock for a military action from CPA and fitted it. The inletting was horrible on the new stock as lower tang was twice as deep as the tang is thick, but upper tang inletting was half as deep as the tang thickness! Had to glue in shim stock in the lower tang in thin pieces, and chisel out the upper to make it deeper.
Just finished it up yesterday, and I'll rub it out with rottenstone powder, and wax it once it's got some cure time.
Before:
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After:
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ssdave
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Re: Ballard stock adaptation/inletting/fitting
Reply #69 - Feb 26th, 2023 at 11:46pm
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Sanded all three stocks today, and put another coat of finish on.  Now another week or at least a few days to dry before repeating.  

Spent two hours on the high wall action, want to get it in the mail this week for color case.  Got all the dings and dents and rounded over edges and such worked out, and everything is square and straight and clean and looks like a factory action, except for a scope mount hole in the top of the receiver ring, and a slight dishing on the lever pin screw on one side that just won't come out without thinning the action too much.   Can't do anything easy with the lever pin hole, but can fix the scope mount hole.  15 minutes, and it's invisible:

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I've got it polished up through 240; will do 320 and 400 and then have to do the lever, block and hammer before sending off for color.  2 evenings if all goes well.  Working for a living gets in the way.
  
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ssdave
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Re: Ballard stock adaptation/inletting/fitting
Reply #70 - Mar 5th, 2023 at 12:37am
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Finished polishing the High wall this morning.  Was a bit slow; got sidetracked into recutting the checkering on the hammer.  Had been buffed and polished out, and wasn't straight, some crossing lines, etc, so had been messed with before.  Started in trying to straighten them out, eventually had to just essentially recut the whole thing, and still didn't entirely clean up the mess, but didn't want to thin it too much.   

The stocks aren't dry enough for another coat of finish, so started in on another project.  When I cut this high wall stock, I made two stocks from the pattern.  Intent was a centerfire rifle and a rimfire.  Pulled out the low wall action and the stock blank that I had 90% duplicated, and started in on the inletting.

For the tangs, I don't use inletting black, I prefer to use lumber crayon; it shows the pressure points better instead of just the rub points; so that it's easy to not overcut and loosen the tangs.  Mark the tang sides, insert into the inletting, shave a few thousandths thickness off of the rub spots, and repeat until the receiver is seated into the wood, and starts hitting at the front of the stock.  I then use inletting black on the action edge to mark the front of the stock, and start cutting high spots off of that also.  Mark, insert, tap with mallet, remove, cut contact spots, repeat 50 times and you're done.  I did this for about an hour and got 95% there, before I quit for the day.

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ssdave
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Re: Ballard stock adaptation/inletting/fitting
Reply #71 - Apr 13th, 2023 at 1:28am
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Haven't taken any pictures or updated for a bit.  Finished up the high wall action and got it in the mail to Allen Springer yesterday.  Had a bit of a delay; sent it to Ken Burklow who engraved the serial # on the tang, just before he passed away.  Was a bit delayed in getting it back, but now on the way to Allen.  The low wall inlet was on hold because I sent both tangs to Ken.  Have been putting finish on the three stocks a coat a week or so, and they'll be ready soon.  Today, started in on the Ballard again.   

It had been polished when I received it as a project, but pitting and unevenness were under the polished surface and unskilled polishing had rolled over the corners.  I didn't take before pictures, but filed the pitting out and squared up the edges and contours.  Then, blocked it square and flat with 120 grit, and then polished sequentially up to 400.  Action is done, did the breechblock also, and I'm satisfied with the action:

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the lever was really badly done, although polished.  It had gouges, pits, scratches and uneven contour under the polish.   Here's some pictures:

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I again filed it to fix the contours and get the pitting and gouges out. Then, put a sanding drum in the Foredom flex shaft, and ground it to shape and smoothed it to a more smooth flowing surface.  Ground a lot of metal off in the process:

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With the preliminary grinding out of the way, did a cleanup with 120; now ready to start working through the grits.  Approaching 2 hours in the lever!

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Re: Ballard stock adaptation/inletting/fitting
Reply #72 - Apr 13th, 2023 at 7:20am
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Dave,
Very good work, really enjoy following your builds, keep it up.  It does my heart good to see others with multiple projects going. 
I have a number of them at almost any point in time.  It appears that you do a little better job of completing a process on one before starting the next - than I do - I find my end results turn out better if I work on a project for a while and then let it rest.  To each our own...  The day job does interfere. Wink
 
Putting a post together takes extra effort and these are very appreciated.   
Thanks,
Greg
  

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marlinguy
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Ballards may be weaker,
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Re: Ballard stock adaptation/inletting/fitting
Reply #73 - Apr 13th, 2023 at 10:49am
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The Ballard levers have so many curves and contours that they take a lot of time to get them right. Yours came out great, and looks as good as what the factory originally did!
The early small ring levers used in 1881 and before like yours, are one of my favorites for a single trigger Ballards.
  

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Re: Ballard stock adaptation/inletting/fitting
Reply #74 - Apr 13th, 2023 at 11:06am
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Nice work Dave.  The action and lever look great and be sure to show us the finished gun.
Bob
  

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