Well, managed to get it drilled, bored, and threaded to .685x40. Bought a new boring head as I was having extreme difficulty in reading the one I bought from Shars. Didn't like the size/capability of the Shars 2" so I upped to a 3". It might be a bit large, but it works great...
The new 3/4x3-3/8 boring bar worked great. Uses a TCMT 21.51 insert.
Rick: Well, the piece of 4140 I bought kinda dictates the final shape. Never having done this, I asked my old mentor what size stock I should buy, and he said 1.5"x1" for a full profile. And it will work well. But had I wanted to pick up the profile of the extended dust cover, I would have had to start with 1.75"x1". Oh well, solves that problem.
I have the comp threaded on fully here and it is flush to the slide (no gap). I may have gotten the threads TOO good as I'm not sure there will be enough room for the Loctite, but time will tell. I cannot detect any play in the threads. It appears I will have about 5 to 8 thou between the breach face and the hood to work with to get the gap as minimal as I'm capable of. I've lost a bit of the fine motor skills over the last 20 years or so.
I thought I'd try one of those new fangled comp alignment reamers from PTG, but it measures at .416" which is WAY more clearance than I used to put in my competition garbage cans (round style). I was thinking more of like .408"? I've never had a bullet strike, but maybe I was overdoing it a bit. But I'll give it a go, and I guess I'll find out how efficient the comp is once I get to shoot it.
The last septum/front face of the comp is not to final dimension yet, and I will take it down to .2" once I get the comp-to-slide interface finalized so I can get the proper angle on it. Once fully fitted and profiled I don't think there are any external right angles anymore. Did I mention I've not tried one of these full profile comps before?
I've never run a profiling end mill either. Hopefully I won't break anything while I'm learning.