No Compromises, No corners Cut, EVER.

No Compromises, No Corners Cut, EVER.

Monday, October 21, 2019

A Custom Fox 20 GA (#007)

This started as a Utica Sterlingworth in 20 gauge and despite the sequence number, it is not the James Bond gun.  Like #001, #002 and #003, this one will remain mechanically a Fox, but it will undergo  extensive cosmetic and corrective surgery.  The transformation (as usual) will be documented here.

The major components in original form (the frame, triggerplate, toplever and forend iron have been annealed).

As is so common with small-frame Foxes, everything is as rough as a corn cob.  Correcting the finish on the standing breech and action flats will necessitate setting the barrels back with an oversized hinge pin, followed by properly "blacking the barrels down".  The triggerplate gaps are a bit easier to deal with.

The cleaned-up frame flats, breech faces and triggerplate fit, along with some rough shaping.

Usually I leave a raised bead around the bottomside curve of the fence, but since the uncaring slobs at the factory didn't leave as much material on the left side of the frame as they did on the right, and the idea of welding on that particular area of the frame doesn't make me feel all warm and fuzzy, I had to do something a bit different.  It turned out to be fortuitous because I think that this looks much better, even though it took much more time to execute.  Obviously, this will continue into the edge of the barrel flats and forend iron.

The bolsters on either side of the toplever were reshaped and sunken coves were chiseled at the area where the topstrap meets the frame.  This was done to create a "layered" look, and the concave edge treatment of the coves ties in well with the lower fence edge.  I also narrowed the topstrap so that the bolsters would overhang the stock, adding to the layered look.  It also allows the upper stock "horns" to be usefully thicker and therefore stronger.  The half-assed convex at the point where the strap narrows was changed to a concave shape that is actually the same on both sides.

Maybe you're wondering about that toplever.  After cutting off the majority of the original toplever, new material was welded on and filed up.  The racy looking concave thumbpad is only on the left side.

Stay tuned, only a couple hundred more hours to go...

Wednesday, October 16, 2019

Repairing an H.J. Hussey SLE 12 GA

The left lock was cocked but the tumbler would not fall.  This usually indicates either a broken mainspring or a broken swivel.  If I could pick one, I'd prefer that the mainspring be broken because in that case, there would be no pressure on it.  A broken swivel however, that's a different story, because when the swivel fails it leaves the mainspring unrestrained inside the inletting but still considerably compressed.  This makes removal of the lock without damaging the wood extremely difficult.  There is no way around it because a sidelock gun absolutely can not be disassembled without first removing the lockplates.  The best you can do is to slowly work the lockplate away from the stock until there is enough room to reach under the plate itself with a blade-type tool and try to hold the mainspring clear of the wood until the plate is out.  This sounds much easier than it actually is.  I managed to remove the lock while causing only a minor chip in the exposed wood.

The failed part.  Swivels are small but are one of the most time-consuming of parts to make and fit because the "pin" ends are integral to the web and they must be absolutely round and concentric from one side to the other for longest service life.

Most factory swivels are hand filed and the roundness and concentricity of the pins are often, shall we say, less than perfect.  The thickness of the web is also often times thinner (and therefore weaker) than it needs to be.  I always make the web of a swivel as thick as it can be while still being able to move freely in its slot, as well as "breaking" all sharp edges in order to minimize stress concentrations.  This also is the reason that such a small part also gets polished on every surface.  I make them from O1 and heat treat them to Rc 48-51.

The left lock, cleaned and reassembled.  Looking at the lower photo, it becomes readily apparent how a failed swivel will complicate removal of the lockplate.

Repairng the chip in the stock caused by removal of the lockplate is next.

In addition to the swivel repair, the gun was completely stripped and cleaned and a couple of dents were removed from the barrels.  The finished job.

Saturday, October 5, 2019

A Side Pedal Fox (#006)

This gun was first shown in stock form here: but it's not going to have much in common with its former self when it's done.

Making an entire gun of one's own design, from scratch isn't the easiest thing to do, but redesigning an existing gun can be far more difficult since one has to "work around" certain design elements that simply can't realistically be altered.  That said, I can truthfully state that this project is the most challenging, from a creative standpoint, that I've yet undertaken.  That's not only because of the side pedal but also the "island" safety, but I get ahead of myself, allow me to fill in some back story.  A few years back, Beretta unveiled a double that they dubbed (double? dubbed? Ha, I kill me!) the "Serpentina".  This gun was quite a departure from anything that had been seen prior, as it was completely smooth, sidelever operated, had the aforementioned "island" safety and highly polished barrels left in the white.  Now, none of these things individually are without precedent but the way in which Beretta combined them resulted in a gun that was unlike anything anyone had ever seen before.  To say that the gun was polarizing may be a bit of an understatement.  The "traditional gun guys" didn't get it while some others saw it as the bold artistic statement that it was meant to be.  The owner of this Fox was quite taken with the Serpentina and contacted me about making something that pulled inspiration from that gun without being an outright copy, something that was just as slick and smooth but which looks more like a gun than a used bar of soap.  The sidelever and island safety were must-haves, as was the completely bald, smooth look but he wasn't particularly keen on the actual shapes of the Beretta.  For the "raw material", I had suggested a Fox, so a Philly-made 16 gauge Sterlingworth was found that had mint bores and also ejectors (another must-have for the client), then the design, or more accurately, the redesign work began.  Shortly thereafter, Beretta raised the bar by presenting the "Serpentina Black" which was again, completely smooth but this time all of the metalwork was finished in deep black and the gun was stocked in  highly polished Gabon Ebony resulting in a gun that was blacker than a Spinal Tap album cover.  Personally, I thought it looked great.  I've long had an idea in the back of my mind for what I call the "Duesenberg" gun, that would be a gun with all of the metalwork left in the white and perfectly polished, with the "wood" finished in a deep gloss black lacquer, along with a few other car-inspired touches.  I guess it could be called the "black and white" gun as well but it was a Duesenberg coupe that gave me the idea, hence the name.  Obviously, the lacquer stock finish would preclude the gun's being used in any remotely realistic way, which is one reason the project had never progressed beyond the idea stage.  I'd never actually considered stocking a gun in ebony until I saw the Serpentina Black, mainly because I'd always assumed that pieces of ebony that big were unobtainable.  Realizing that that was an actual option and having secured a suitable billet of ebony (you think English walnut is pricey?), I contacted the client and suggested that we go with the "black and white" motif.  He enthusiastically agreed.  The gun will be completely devoid of engraving, checkering and even screw heads, in other words, completely smooth.  Achieving this look necessarily also means that the relief cut in the frame that accommodates the forend iron must be dealt with.  I've done that in the past with a spring-loaded, articulated cover but those were extractor guns.  The ejector mechanism in this forend doesn't leave much room for the cover mechanism but, where there's a will, there's a way.  Obviously, this is no cakewalk and will require major redesign and surgery but the end result will be like nothing else.  Here goes.

First off, here are a couple of photos of the gun as received.

Here are some of the parts that will not be used.  The topstrap, rib extension and forend lug will join this group as well.

 After complete disassembly, the frame and triggerplate were annealed and the topstrap was removed in preparation for the new leverless piece.  The dropped areas on the new topstrap are what will create the island safety.  Converting the gun from a captured stock to a drawbolt stock killed two birds with one stone.  It accommodated the island safety while hiding the breech screw in the most effective possible way, by getting rid of it.  That bar of 1020 with the blue arrows pointing to it is the material from which the new topstrap was made.

Once the design of the sidelever and bolting mechanism was proven using wood mockups (old-school rapid prototyping), the actual parts were made in the steels appropriate for their role.  Before I actually made the new bolt, and before the topstrap was welded in place, I took the opportunity to true up the bolt bore in the frame since they are neither round nor cylindrical as they came from the factory.  They're also about as rough as a corncob internally as well.  The form of the sidelever was taken almost directly from the Serpentina, per the client's request as that is his favorite single part of the gun.  Aesthetically, it will work well in this application.  Below are some photos of the roughed out sidelever and its inspiration, all prior to welding.

The topstrap/frame junction, after welding and rough shaping of the contours at the wood/metal interface.  The lever is roughly shaped and the bolt and link are made.  At this point, the only external frame shaping that's been done is that which is incidental to the structural modifications.  Once all of the internal mechanisms are made, I'll get to the external shaping.  The next items on the agenda are the return spring mechanism for the bolt and the safety mechanism, which will be unlike anything seen on a double, not a slide, roller or a lever.  In case you're wondering, no, the sidelever does not pivot on the sear pin axis.

When I filed up the new topstrap, I left the safety island high because the top line of the hand portion of the stock would define the height of the island.  Normally I don't start on the stock pattern until later in the process but much like when making a bar-in-wood design, the stock in this case determines the shape of certain elements, namely, the safety island.  So I had to mock up at least the hand portion of the stock.  The parts of the safety mechanism could not be made until the height and contour of the exposed surface was defined.

Here is the blank.  Even at this exposure, it's apparent how black this piece of ebony is.

Friday, October 4, 2019


It's been a while since I've posted anything because I've been inundated with repair work (A.K.A. "dirty dishes" work) but with a portion of that out of the way, the interesting stuff can resume.

The scratchbuilt 28 gauge detailed here: is is almost ready for stocking and then finishing.  Once I make the forend fastener and forend finial, I can begin with the stocking.  I found what, at the time, seemed like a nice blank but I think I'll save that for another project.  It's nice but not quite nice enough for this gun.  Rather than make multiple separate posts detailing the entire project, I'll simply add to the original post.  I think that this will make for a less confusing format as all of the information will be in one place.  Just click on the link and you will see the updated post. 

A couple more interesting custom Fox guns are in the works and will be posted so that you can follow along with those.  They are numbers 006 and 007.  Number 007 is an extensive cosmetic makeover but it's still mechanically a Fox.  Number 006 is something else entirely and the beginnings of that project will be posted presently.