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Hot Topic (More than 10 Replies) Makeover for a Stevens Model 44 (Read 1712 times)
rnnhntr
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Re: Makeover for a Stevens Model 44
Reply #15 - Jul 6th, 2025 at 12:50pm
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I finally got moving on this project. The lever is fitted to the action and all works as it should. For those of you who may want to try this, here is how I did it. Note: Your results may vary. To start with, the following sketch has the dimensions I took off of my action and original lever.
  
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rnnhntr
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Re: Makeover for a Stevens Model 44
Reply #16 - Jul 6th, 2025 at 12:58pm
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The first step was to machine and then stone the lever to width. Fortunately, the casting from CPA has the sides parallel. I milled each side down approximately 0.014" which left the lever about 0.002" oversize. I then stoned each side to polish and final fit them so that the lever slides into the bottom of the action and moves freely, but has no slop. The following pictures show the lever as received and a couple post machining compared to the original lever.
  
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rnnhntr
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Re: Makeover for a Stevens Model 44
Reply #17 - Jul 6th, 2025 at 1:01pm
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My next step was to drill the holes for the pivot pin and the link pin. I found that an L-size letter drill worked for the lever pin hole and a #13 drill worked for the link pin hole.
  
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rnnhntr
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Re: Makeover for a Stevens Model 44
Reply #18 - Jul 6th, 2025 at 1:20pm
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The next step in the process was to file the head of the lever to shape. I laid the old lever on the new and used the #13 and "L" drills as guide pins to trace the outline of the old lever onto the new one. Then it was a matter of files and stones to get the shape correct.

Unfortunately, I forgot to take pictures of the next two steps, which were to mill the slot that the link fits in and drill the hole for the lever plunger and spring. I used a 1/4" center cutting end mill for both steps. I laid the old lever on the new and used the #13 and "L" drills as guide pins to to mark the angle for the link pin slot and then clamped the new lever in my mill vise with axis for the bottom of the link pin slot parallel to the mill table. After milling the slot I indexed the hole location and plunge milled the hole. Getting the pivot slot and plunger hole locations and depths correct was the hardest part of fitting the lever.
  
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rnnhntr
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Re: Makeover for a Stevens Model 44
Reply #19 - Jul 6th, 2025 at 1:24pm
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I was fitting as I went, but the final assembly of the action still took some polishing and fiddling, but it all went together and works as it is supposed to. I am starting on fitting the barrel next. I will wait until I have the barrel fitted and the stock work done before polishing and finishing the metal. 

I am guessing that I have between 8 and 12 hours of time in doing this first one and I would absolutely not try this without a good milling machine. All that said, having now done this once, I will probably do another for a plain-Jane Stevens 44 I have that started as a .25 Rimfire and has been relined to .22LR.
« Last Edit: Jul 6th, 2025 at 1:37pm by rnnhntr »  
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