H&R Fore end spacer project

SEK_22Hornet

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I'm a newbie to machining with no training, trying to learn how to do a few machining operations. I have several projects in mind, mostly gun related, so Friday I decided it was time to get down to business. As I posted earlier, one of these is making some barrels for my rifles, but I think that will wait a little while. I really want brass fore end spacers on my Buffalo Classic and Carbine, so I decided I'd see what I could do. I have a little aluminum scrap that is the right size, so I decided to see if I could actually get something that would work made before spending $50 for brass stock. Here is where I'm at right now - I'm actually pretty pleased with my progress. Mainly need to cut it off and machine it to length and drill and countersink the holes. That probably won't happen until I get a nice warm day again (my shop is unheated). Here are a few pics - comments are welcome (and encouraged). I realize I should have taken some photos while in the process, but didn't think about it. I'll try to remember when I get back into the shop. I'll probably make a second one out of aluminum before moving on to brass just to make sure I'm comfortable with my process.

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That's good looking work. The bulk of my machining is in gunsmithing and I actually have to make one of these as well. Looks like you have the process down very well. I would like to see pics of the set-ups you used to cut the radii.

Again, nice work.
 
Thanks - I'll try to get a shot of the set up - I used a small 4" rotary table on my G0704 Grizzly mill with a small milling vice mounted to it.
 
It isn't a perfect fit. but it is within a few thousandths. I used a 1-1/8" milling cutter to cut both the barrel and pivot radii. The outside radius was cut using a rotary table. Here are a couple photos - not while I was cutting the part but the two mills were still set up so I just clamped the part in a took a quick shot.

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Thanks for the link. That's a neat kit. I wonder if the vise can be purchased separately. I thought the outside radius was done on a rotary. Inside I thought you may have used a boring bar or fly cutter on the mill. The fit looks better than the factory.
 
I hope to get back into the shop this weekend and finish the prototype, maybe even get started on some fixtures. I want to make at least 3 of these for myself and I suspect I may be able to sell some if I make a few extras. I found some brass cut-offs on ebay so I have some brass coming to get started once I get the process and fixtures down.

Edit - I made a stop at the local scrapper after work and came away with a nice chunk of brass bar stock that should work nicely - 3/4" x 1-1/2" x 11-1/2" long, 4 pounds @$3 / pound.

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