AmericanLongRifles Forums
General discussion => Gun Building => Topic started by: smart dog on November 24, 2019, 02:42:32 AM
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Hi Folks,
This project began with a phone call from Dave Keck. He said he spoke with a young man, Josh Tabor, from Vermont who was blind but was wanting to build a rifle and called him about a stock, barrel, and parts. Dave understood clearly that there were some issues involved and the caller was a bit confused about the building process and long rifles. He called me and asked if I could help Josh out because he was not sure he was able to do that very well. I do what I can to take care of my Vermont family so I contacted Josh. Josh was blinded and hearing impaired by disease when he was very young. He grew up in a farming family and has had a rough time because services for people with disabilities in rural America is pretty limited. He loves historical re-enacting but that community was lukewarm to him because of his blindness. He competed in primitive winter biathlons and woods walks in Vermont and harvested turkeys with a muzzleloader. He dreamed about building and owning a long rifle. I found Josh to be smart and able and decided to help him build a long rifle, which he will use in woods walks and hunts. Josh and I have no illusions about the gun building process. There are many steps that he cannot do but there are also many that he can, and I am committed to discovering just how much he can do. So we have started building a long rifle. He had an older Getz barrel, 54 cal, 38" long, swamped that was probably made for the early Haines kits. It was given to him by a friend. I had an older Siler lock that needed some upgrading, and bought parts to make it into a really first class lock. A local muzzleloading store owner had a good curly maple stock blank, which he sold for to Josh for a very small sum. The up shot is we are on our way. Dave Keck did an expert job inletting the barrel and drilling the ramrod hole. We designed a nice early Lancaster style gun and Josh is working with me to build it. Certainly, there are many tasks that I have to do but there are also many he can do and we are devising means for that to happen. Here are some early photos of Josh inletting the the bolster on the breech plug. One challenge was figuring out a way for him to hold the chisel perfectly vertical. He had a natural tendency to angle the chisel away from him. So we developed a rule that said place the chisel at the angle you think is vertical and then rock it back toward yourself a little. It worked. He got the bolster inlet quickly with minimal guidance. When he correctly flicked out the first chip of wood from the mortice, he smiled like a man really happy. This project will be a challenge but fun.
dave
(https://i.imgur.com/MNPGxXA.jpg)
(https://i.imgur.com/6YLK9fp.jpg)
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now this is about the coolest thing ever.
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I can't imagine this scenario, but do wish him all the luck in the world. I've got serious eye problems which forced me to cease building, but I still drive and can watch TV. Dave....you're a wonderful guy to do what you think is best for Josh. Looking forward to the completed LR. WOW!.....Fred
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Dave
What a great opportunity for both of you!! You are to be commended Dave!!!!!
Mitch
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Dave, I just don't have words to adequately say what is in my heart. You da Man,so is Josh. What a great story. Best regards to both of y;all. Dave F in WV 8) 8)
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Dave & Josh, My hats off to you both - Josh for having the courage and conviction to not let anything keep him from his goals. Dave for taking the time to share your outstanding skills and knowledge to help him achieve them. God bless you both.
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This is fabulous. Blessing to you both. Please keep us updated on this story.
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Dave this sounds like it might be one of yours and Josh,s more challenging efforts. My very best wishes go out to both of you.
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Dave,
I don't have much, but would donate a couple parts if I have them for this build. This is a great story and an inspiration to say the least.
Mike
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Hi and thank you all,
Here is the finished barrel tang. There are a few gaps but Josh did really well. We are using tape to mark outlines that he can feel. That seems to work pretty well. I also will cut a deep outline groove that he can follow and insert a chisel into my cut. We are figuring out tricks but don't get me wrong, much of the work I will have to do. However, he and I come up with new ideas every session that get him directly involved in the process more and more. Get ready for some astonishing things.
dave
(https://i.imgur.com/UjDs8cL.jpg)
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Yeah, man !! Go for it. Looking good. This has made my day,probly several days. Dave F 8) 8)
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"I can't imagine this scenario, but do wish him all the luck in the world. I've got serious eye problems which forced me to cease building, but I still drive and can watch TV. Dave....you're a wonderful guy to do what you think is best for Josh. Looking forward to the completed LR. WOW!.....Fred"
I am sorry to hear that Fred. Seeing your guns you've posted in the past sure has brought me a lot of enjoyment. More for their owners I am positive. God Bless, Marc
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That's awesom man! God bless your work for helping with this project! Very inspirational!
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Hi,
Thanks everyone for looking and commenting. The project will be a challenge but the story is not about me. It is about Josh and his determination. Mike, thank you. That is a generous offer but I think we have all the parts we need. I am going to see how many Josh can make by hand. The project will go slowly because Josh lives about 40-50 miles away on the other side of the Green Mountains and there are very few transportation options available for him in rural Vermont. His wife works long hours and can only bring him over every few weeks. I meet them half way. Rich, Tom, Larry, and John might remember the powder horn Josh made that I brought to Dixon's. It's an astonishing horn given he has never seen a powder horn. He's never seen a long rifle either, except with his hands. He currently shoots an old flintlock NW trade gun by Sitting Fox, I think. He brings the gun up to his shoulder and has a friend sight it from behind, telling him when to squeeze. However, only Josh touches the gun. As you can imagine, he does not do well shooting paper but does pretty well with larger metal animal targets and the "ding" gives him instant feed back. A short side story: I picked up the stock blank from a vendor in VT and delivered it to Josh. He packed it up with the barrel and shipped it USPS to Dave Keck. En route, the barrel fell out in one of the trucks because Josh did not reinforce the ends of the box very well. Dave called me when he opened the box and only saw the stock. I called Josh and he went down to his local PO and they very quickly tracked down the trucks used for the transport and had someone check them. Within a couple days, the barrel was delivered to Dave. Rural POs, where they know everybody in town, can be a great asset.
dave
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I did my last by hand inletting on a rifle build that is still only a barrel in a piece of black walnut.
It was a simple rectangular tang.This young man's inletting is something to be very proud of
and I hope we get to see this project as an ongoing thing for however long it takes.I had some
visual problems but two operations to remove cataracts and new glasses for close work and
all is well at least for a while.Dave, YOU are a real man and we are proud of you and your giving
time to help this young man.
Bob Roller
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Dave, you never cease to amaze me, your kindness, your skill and your heart are what this world needs today. Bless you
Jon
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R sum!
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Dave, you are to be commended for your kindness and patience. God bless both of you as I am sure he has.
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Wow! I look forward to following this thread. Best wishes to all involved.
Kevin
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This story is amazing 8). Josh sounds like a pretty amazing guy indeed. I can not begin to understand how he does this even with your help. All the best to Josh and you Dave ;D
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This whole concept goes right to the top!! Good on you Dave. I know Josh appreciates your commitment and generosity.
Fellow builders: we can take a page out of Josh's book...here's a man who is not afraid to try or to make a mistake, or step out on a limb of unknown safety.
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Hat's off to you both Dave.
This is the far-outest thing I have heard of in a build, and a great tribute to you both!
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Absolutely incredible. Hat's off to you, Dave, for taking this project on and working selflessly to assist this young man.
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Dave, what a great thing your doing !
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Dave, wow, that's a heck of a good thing you're doing to help Josh realize his dream.
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I can't even begin to imagine the challenges this young man faces to enjoy his hobby. You and he are to be commended for attempting this endeavor. Best wishes to Josh in his pursuit of a dream. You're a good man Dave.
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Smart dog, you are walking the walk and it is something special to see. Thanks.
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Good Man Dave.
Tim
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Dave
Your selflessness and commitment to a difficult project helps the rest of us put our lives into context. Thank You.
Clint
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God bless both of you
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Hi Guys,
I am overwhelmed by your support and comments. Thank you all. The story is about Josh, not me. I am just the facilitator helping the project along and seeing how far he can go at a task before I step in to guide him or take over. I have to be honest in that I was originally very skeptical about the whole thing but was convinced by Josh's determination. He is tenacious. I am backed up with gun work so I had to figure out how to fit his project in with my regular gun shop work. I've always been comfortable around people with disabilities. For years, I coached X-country skiiing for Special Olympics. As a result, I am very candid with him about his limitations but also very supportive of him pushing the envelope of those limitations. I'll give you an example. We needed to fit the breech plug and shape the tang. I wanted to square up the bolster first. This was a good opportunity to get Josh filing. I told him what needed to be done and why, and gave him the proper file. I got him started filing and then stepped back and just watched for a while. He had a tendency tip the nose of the file down from level. The bolster was the perfect trial balloon because we had a lot of excess metal to work with. It became apparent to me that Josh needed to find his natural stance relative to the object he was filing. I mean that in the same way an offhand shooter needs to find his natural stance in which his body has the right tensions to remain neutral such that he doesn't tend to twist left or right. We needed to find Josh's natural position relative to the work so he did not angle the file up or down and kept it level. That meant moving Josh and the breech plug around until we found that sweet spot and then determine a rule or metric for him to always find it. It worked! He can file a perfectly level surface as long as he finds his natural position. This is the kind of thing that should help all of us.
dave
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That is the coolest I am benefiting just from knowing
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Dave,
I greatly appreciate the process if this build, and you working with him to find things that all of us can benefit from.
Mike
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This is a wonderful project both of you have ventured on. My hat’s off to the both of you. You’re a very kind man, Dave and surely have a very determined partner. Nothing can stop a combo like that!
Bob
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Dave I'm late as always. But I commend you highly on helping the young man out. Truly a selfless jester on your part. To Josh it is amazing he would attemp this. But most people who have or been dealt difficulties in life. Take all this in stride an not afraid of the challenges ahead of them.
Thanks for helping him out.
Oldtravler
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It is only in great challanges that we find out who we really are. People like the two of you give me hope in humanity. Thank you, both of you!
Gerald
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Dave,
Please let Josh know that I look forward to his completion of this project and will be pleased to shake his hand at Dixons next year.
I appreciate your humility and applaud his tenacity. I am humbled by both.
Kevin
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I salute the both of you.
Best of luck,
Jeff
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My hat is off to you, sir. You are to be commended. If everyone in this world could do a similar kindness for a fellow human being, this world would be a better place. Best of luck to you both.
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God bless both of you.
Percy
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Years ago, I made a set of measuring gauges for John Rook, a blind Bowhunter, who wanted to make wooden bows. I marked the gauge in Braille for the gap size, so he could use them to feel the width and thickness of the bow as he shaved it down. He made several bows and shot several deer with them before he passed away. He was an amazing person who never gave up because he lost his sight.
Similar tools might help your young man keep the stock width and depth even as he works the wood down. I wish him good luck and congratulate him on his courage and will to tackle this project.
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Wow! Hats off to you both! Awesome job!
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Dave,
I am at a loss for words. I look forward to meeting this young man.
I am proud to know you.
David Price
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Hi Folks,
Josh was able to get a ride over the mountains today and work in my shop. As planned, I picked him up halfway. I wanted Josh to disassemble and reassemble a flintlock by himself. Yesterday, I blindfolded myself and attempted the task and it went very smoothly. In the process, I figured out some tricks that should help him. I originally donated an old Siler lock to the project but that lock really needed some work and I just did not feel like working it over right now. I had a Dale Johnson lock lying around and it fit so nicely in my drawings of Josh's rifle, that I decided to donate it to the project. I had Josh take it apart, however in the process, I realized he has never seen a flintlock. My blindfolded practice was easy because I could envision every component of the lock. He cannot. So I had to teach him to feel every part and understand its function. It took time, but Josh mastered it, even the fly. He works low over a tray so any dropped parts don't get lost. A big shout out to Tom Curran's (Acer) spring vise. It was a huge benefit to Josh.
(https://i.ibb.co/Bgybgrq/disassembling-the-lock-1.jpg) (https://ibb.co/CnbgnMh)
(https://i.ibb.co/Vp9D7G5/disassembling-the-lock-2.jpg) (https://ibb.co/dJM6dvx)
I taught Josh how to use files. I had an idea that his body position relative to the work would affect his ability to file level or at a consistent angle. I was right in this and we worked on him finding the right body position to do the job at hand. This is a major break through because it means he can file confidently. I had him file the draft on the edges of the lock plate.
(https://i.ibb.co/gZYX0wS/filing-draft-on-the-lock.jpg) (https://ibb.co/tpRN0cq)
Next, I had him practice inletting a lock plate. We tried several methods. First I cut a deep tracing of the lock on wood and he used the cut as a guide to stab in the outline. We also tried outlining the shape with tape the edge of which he can feel. Both methods worked up to a point but it was still hard for Josh to keep the chisel blade in the cut or flat against the edge of the tape. We will work on this but for now I opted for another method. I started the actual lock plate inlet, established the shoulder indicating the borders and he used that shoulder as a guide. He then deepened the inlet, back cut the borders and relieved the bottom of the mortice. I cleaned up and evened the bottom and the lock plate was in. I checked it with inletting black.
(https://i.ibb.co/N9yWRPY/inletting-practice.jpg) (https://ibb.co/sKVs7G3)(https://i.ibb.co/2SpDG40/inletting-practice-2.jpg) (https://ibb.co/PMV7qHs)
(https://i.ibb.co/dgs2FXG/inletting-practice-3.jpg) (https://ibb.co/zJWRpCG)
(https://i.ibb.co/BGJ48rm/inletting-lock-plate-1.jpg) (https://ibb.co/RNKhLB1)
(https://i.ibb.co/VmLX7wZ/inletting-lock-plate-2.jpg) (https://ibb.co/zJmKy6Y)
Josh and I joke a lot. At first I kept asking him if he had enough light. He woulds always say "no", could I adjust it better.
dave
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So, he's got a sense of humor! Both of you are doing a great job, Dave! I'm looking forward to the finished rifle.
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This goes to show us we are only limited by the limitations we impose upon ourselves. If we allow ourselves to try without the fear of failure then we can accomplish the impossible. Easier said than done, but this effort is a shinning example. Congrats to you both.
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Wow, so amazing! I always enjoyed having students in my shop, you have taken that completely to another level. Looking forward to the next installment. BJH
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Great story to start the new year. What you’re doing is the sort of thing that can change a life beyond what you might imagine. Well done.
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Hi Folks,
It has been hard for Josh to get over to my shop because of his wife's schedule and it stormed on the last 2 dates we were able to set, preventing travel. Anyway, he made it today and we installed the barrel lugs. The barrel, barrel tang, ramrod groove and hole, and lock are now all inlet. Before starting shaping the stock, I wanted to get the barrel lugs installed. We are going to use captured barrel keys not pins. That will aid Josh taking out the barrel without risking losing small pins and figuring which pins go where. Josh used his Braille rulers to measure and mark where the lugs were to be installed. We discussed the issue of spacing and avoiding interfering with the ramrod thimbles. Josh worked out his solution and away we went. I had barrel lugs that I previously made but they needed the ends filed to 60 degrees. This is when we really tested our idea of finding the bodies "sweet spot" for filing straight or level. I showed him how to hold a lug in the vise and use a triangular file to set it at the proper angle to the vise to file a 60 degree dovetail. To do that he had to file level with the vice jaws and I watched as he set up to file and then had him shift one leg back (open his stance) which automatically set him up to file level. Remember, he cannot adjust his actions by sight so relies entirely on feel and body position. We proved the concept and I would urge everyone to think about it. When working for precision in shop work or shooting, don't fight your body. Make it work for you.
(https://i.ibb.co/zNf9nFp/filing-barrel-lug.jpg) (https://ibb.co/DLKcVYh)
I cut the slots with a hacksaw but had Josh file the slots flat and the dovetails. He used the depth gauge on my calipers to make sure the slot was to the proper depth, however, I set the depth. I also cleaned up the slots and dovetails but only a little. After tapping in the lugs, he filed the excess metal on the bases flush with the barrel flats.
(https://i.ibb.co/JzQbRPm/filing-lug-dovetail.jpg) (https://ibb.co/K9wQjHb)
(https://i.ibb.co/QnV0BM5/filing-lug-flush-with-barrel.jpg) (https://ibb.co/K7gnZW1)
(https://i.ibb.co/10tCscs/Josh-s-first-lug-installation.jpg) (https://ibb.co/TwxQKyK)
Next up was inletting the lugs in the stock. I had Josh use his Braille ruler to mark the lug base locations on the stock.
Then I used inletting black to mark the locations of the actual lugs in the barrel channel. There is no way he can see those marks so I cut the slots in the wood for the lugs. However, he could measure the borders of the lug bases, which were raised a little above the barrel flats and had to be inlet. I helped him mark those borders with a chisel and he cut out the mortices. It worked out very well.
(https://i.ibb.co/hVX2LMG/feeling-for-edges-of-lug-inlet.jpg) (https://ibb.co/bXHNQ34)
Before cutting the slots for the barrel key, I wanted to trim the sides of the stock. I cut off the excess wood and then showed Josh how to use my jack plane to even and square up the sides of the stock .
(https://i.ibb.co/Jd0nRNb/using-jack-plane-to-square-and-smooth-stock.jpg) (https://ibb.co/xsPhSyc)
That is where we are and more to come but be patient.
dave
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Brilliant! Bless you Both!
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That looks better than my first five rifles, I think.. Hats off to you and your student.
When my wife and I were youth group sponsors at our church, we took a teenager work’ group to a camp for blind children. The fellow who started the camp was blind. You’d never have guessed it. He confidently traversed the whole place ( which was out in the middle of nowhere) without a problem. He did things that you’d have thought impossible without a second thought. (As I recall he was an avid turkey hunter.) It was amazing. Those kids in that group learned something on that trip. Never underestimate a man with a mission.
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Hi,
Josh was able to get over the mountains yesterday and we had a good long day of work on his rifle. We went from this:
(https://i.ibb.co/tzgRcRB/using-jack-plane-to-square-and-smooth-stock.jpg) (https://ibb.co/0KT5Z5q)
to this:
(https://i.ibb.co/jJ45h0q/where-we-are-at-feb-29-5.jpg) (https://ibb.co/KKyG64B)
in one good hard working day.
I had Josh start off by planing facets on the fore stock as we pare it down evenly and shape it.
(https://i.ibb.co/pbzQwRt/planing-down-forestock-1.jpg) (https://ibb.co/RY0NbBx)
(https://i.ibb.co/zb0bbnH/planing-down-forestock-2.jpg) (https://ibb.co/3WLWWrY)
(https://i.ibb.co/gjF3bZH/planing-down-forestock-3.jpg) (https://ibb.co/X2kbfxN)
Then using my pattern maker's rasps, he filed facets where the plane could not reach.
(https://i.ibb.co/9bS1fSf/rasping-forestock-1.jpg) (https://ibb.co/0Cv6WvW)
Next up was thinning and shaping the forearm using pattern maker's rasps.
(https://i.ibb.co/CM7vYxt/rasping-forestock-2.jpg) (https://ibb.co/MGVptqh)
(https://i.ibb.co/7gCX7xC/rasping-forestock-3.jpg) (https://ibb.co/z8xrKWx)
After that I had him start to shape the wrist after I trimmed off some excess wood with the band saw so were were right down to my outline on the wood. I taught him to do it the way I demonstrate at Dixons using pattern makers rasps.
(https://i.ibb.co/ySCtWjX/shaping-wrist-1.jpg) (https://ibb.co/FV12gTK)
(https://i.ibb.co/wz5dMrq/shaping-wrist-2.jpg) (https://ibb.co/jrn8gZY)
Notice how Josh holds the upper end of the rasp with his finger extended. As he moves down the stock, his finger is feeling the wood for the end of the area to be worked in that task. When he no longer feels a rasped surface but the smooth wood, he knows to stop and go back the other way.
A happy gunsmith's apprentice
(https://i.ibb.co/ScHVJKG/having-a-good-day-1.jpg) (https://ibb.co/VxbM3v5)
I do the drawing of all guidelines on the stock and usually start the task at a certain section, which then allows Josh to feel where the boundaries are for planing and filing for that task. Then I just let him have at it until the task is done. Sometimes I even up his work but lately, that is not necessary. He is figuring out how to do clean accurate work.
Well, here is where we are at the end of the day. I installed barrel keys for Josh and they came out really nice.
(https://i.ibb.co/7WkkXsr/perfect-barrel-key-inlet.jpg) (https://ibb.co/WyVV6mB)
(https://i.ibb.co/qNT3cKZ/where-we-are-at-Feb-29-1.jpg) (https://ibb.co/dP8wVFh)
(https://i.ibb.co/R0XX617/where-we-are-at-feb-29-2.jpg) (https://ibb.co/VSFFCd3)
(https://i.ibb.co/LQzyQK0/where-we-are-at-feb-29-4.jpg) (https://ibb.co/xmSbmZ2)
(https://i.ibb.co/jJ45h0q/where-we-are-at-feb-29-5.jpg) (https://ibb.co/KKyG64B)
(https://i.ibb.co/d0n8yg1/where-we-are-at-feb-29-6.jpg) (https://ibb.co/jv7nFRB)
(https://i.ibb.co/NWSyQXv/where-we-are-at-feb-29-7.jpg) (https://ibb.co/wpsz3Tk)
More wood comes off everywhere as we progress but it is starting to look like a rifle!
dave
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That's a lot of whittling for one day. Looks good.
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Amazing!
Bob
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Josh has something that I wish more young people have, and that is a strong work ethic. He assesses the work to be done, and how to do it, then has at it.
Thanks for teaching him, and the rest of us, good stock making practices. That will remain with him for the rest of his life, and he may be able to inspires others, also, thus carrying on the traditions.
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wow Dave amazing project and challenge.
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Hi,
Finally back at it! Josh and I felt it was safe to get going again in my shop. His wife works in health care and is tested frequently and virus cases where Josh lives are very few with no new cases in over a month. Same where I am so we figured it was OK to get some work done on his rifle. I installed his butt plate and inlet his trigger so we could test the fit and adjust things if needed. So far it seems to fit him well. Next up was inletting the ramrod pipes. He had some cast ones so we used those to speed things up rather than make them from sheet. The photos shows a pipe on which I filed a notch in the tab. the notch or notches indicate to him which pipe he is handling and the direction toward the muzzle it should be inserted. I determined their locations on the stock.
(https://i.ibb.co/VSfyVfc/inletting-ramrod-pipe-4.jpg) (https://ibb.co/SnFTNF4)
Then I marked holes in the stock for the tab and he drilled them out. Next, he cleaned the slots with a little saw and thin flat file. Next, I cut the outlines and Josh cut the mortices with a gouge. Note how he has to hold the gouge a little oddly so his pinky or ring finger feels forward of the tool so he can tell where to stop the cut. I also gave him a lighter wooden mallet with a big rectangular head which helps him tap the chisel but also keeps the blows light.
(https://i.ibb.co/84Wp6gN/inletting-ramrod-pipe-1.jpg) (https://ibb.co/FqSMg4m)
(https://i.ibb.co/jRntFMS/inletting-ramrod-pipe-2.jpg) (https://ibb.co/zJqdwRz)
(https://i.ibb.co/dQQVnxn/inletting-ramrod-pipe-3.jpg) (https://imgbb.com/)
He did a fine job. When the depth was cut, I took over and using inletting black, checked the fit. The pipes came out very well.
(https://i.ibb.co/qgNHWMJ/inletting-ramrod-pipe-5.jpg) (https://ibb.co/s1KT6vW)
Josh gets nervous when I put black on parts because when he asked me if I would tell him if he accidentally smeared black on his face, I told him "no" . Then he asked if I really wanted him to go out in public with inletting black smeared on his face and I said "yup". I have to be careful because he is a skilled martial artist. Because the pipe portion of the rear pipe is identical to the other pipes, I had Josh inlet one of the other pipes at the position of the rear pipe. Then it was just a matter of me inletting the tang. It worked pretty well. I did it that way because the job really requires inletting black most of the way through to remove pinch points.
(https://i.ibb.co/94gFhMg/inletting-rear-ramrod-pipe.jpg) (https://ibb.co/5j4Nk74)
Finally, I had Josh remove more wood from the fore stock. To help him keep things even, I have him rasp flats using long strokes. I position the stock in my vise so he can file a flat while holding his rasp horizontally. He's learned how to do that and adjust for his body's tendency to tilt the rasp from horizontal. So he places the rasp on the stock, holds it where he thinks it is level and then rocks it toward him a tiny bit, which achieves true horizontal orientation. We increase the number of flats and the stock eventually becomes evenly rounded.
(https://i.ibb.co/vBvV5jZ/taking-more-wood-off-fore-stock-1.jpg) (https://ibb.co/PYzFp6w)
Next time, we shape the butt and cut the cheek piece.
dave
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Dang Dave,
Josh does a neater job than I do, and I can see what I’m doing. Must have an incredible sense of feel, and spacial awareness.
Thanks for doing this, Sir!
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Hi Dane,
Yes, he is doing well. He goes slow and has taken to heart the idea that you can always remove more wood but it is harder to put it back (except of course with super glue ;D). So he shaves a little at a time and if he gets in trouble, the error is not very much and can be corrected. The problem for Josh with super glue is that he keeps gluing his fingers to inappropriate parts of his body. Then I have to help him get unstuck. I am not sure which of us is more embarrassed by that.
dave
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All the more reason to make sure he keeps his hands out of his pants I guess!
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This is a great story thanks for sharing Dave, Josh sure looks like he is having a good time! You are creating memories that will have a long life and provide inspiration something you might want to put down in writing many will benefit.
Many years ago I was contacted by a paraplegic who wanted to train her border collie for stock work. She called me because she had call a few others who said they were not equipped to work with someone in a wheelchair on rough ground. When I talked with her she was determined so I arranged her to go to a friend of mines farm in Connecticu where the ground was relatively level. She was not only in a wheelchair she could only use one arm and had limited ability to talk. Between my friend and I helping her we got her to be able to work her dog verbally close at hand in a round pen. She did that for a few months about every two weeks and made some progress with her dog but she could not whistle and had to use a blow horn to command her dog. A few weeks after I saw her she called me and said she was determined to run in a trial. I told her she was limited by her dog that she needed to find a trained dog to teach her. She knew that and asked me if I would help her to find one and I told her I would. I put the word out and a fellow I knew out in Idaho called me and said he might have a dog that would work for her. Ilsa spent the winter in Florida and I put her in contact with that friend of mine in Idaho. Low and behold he flew to Florida and found a farm for her to work sheep at to try out her potential new dog. It was a match the dog loved Ilsa and she loved her and the dog worked well with Ilsa's limitations. Don, the guy from Idaho stayed down long enough to get the pair established and find a good trainer for her to work with. When the season started Ilsa called me and told me she entered her first trial and wanted me to be there to see her run and I told her I would be. Not only was I there but so was my friend from Connecticut and she did very well not winning her run but placing in the top ten. When she came off the field she was very emotional and came over to us and the only thing she could say to us was thank you. It was a big moment for her and quite an accomplishment. I was proud of her she overcame a lot but she had a goal and she met it. I was also proud of all the people in the sheepdog community that offered there time and help for her. I am sure it means a lot to Josh and I am impressed with his work and deterination and your willingness to help him.
Rob
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Hi Folks,
Thanks for the comments and I passed the support on to Josh. He appreciates the encouragement very much. We got quite a bit more done. Josh is able to get over here every Saturday or Sunday so we can make steady progress. It is slow though because it takes him more time to get tasks done but that really doesn't matter. I had him clean up the pipes with fine files and they are ready for final polish later.
(https://i.ibb.co/94HPxhJ/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/Zgz9QS3)
(https://i.ibb.co/WfTVv5c/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/XtwYxLz)
He did a lot more shaping of the stock using a pattern maker's rasp and coarse file and we roughed out the cheek piece.
(https://i.ibb.co/bJsr9CB/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/3zp0ZjN)
(https://i.ibb.co/rsWR10R/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/jRpP1fP)
(https://i.ibb.co/Dk2p6z6/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/jGXRxbx)
Next we made a trigger plate from steel and I had Josh file the trigger slot and clean up the edges of the plate. Then I drilled the tang bolt and used the hole to position the trigger plate. I had Josh inlet it. He did the complete inlet by himself. He did a good job but you can see a few gaps and one place near the tail where he cut outside the outline of the plate. No problem, a wood chip and super glue to the rescue.
(https://i.ibb.co/LJwPx6V/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/rcPtxMD)
(https://i.ibb.co/zhyG8nh/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/sv0y5mv)
(https://i.ibb.co/VQnPCK9/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/KL43s1h)
After inletting the trigger plate and positioning the trigger, I had Josh bring the forestock down to almost finished dimension. I have him use a method of planing, rasping, and filing flat faces like the flats on an octagon barrel. He then increases the number of flats on each side until the cross section of the stock is round and even. It seems to work well for him. After paring down the fore stock, it was time to make and install a muzzle cap. I shape the wood where the cap will go first and then use it as a form for bending the brass sheet to make the cap. To begin, I marked where the rear edge of the cap will meet the wood with masking tape. Then I had Josh use a very fine Japanese saw to shallowly cut along the edge of the tape. These saws have no kerf and cut on the pull stroke creating very clean and precise cuts. I rarely ever have to go back and clean up the edge of the wood for a perfect fit to the cap. After sawing the edge, I had Josh back cut the line with a chisel to create a trench he could feel. Then he used a coarse file to take down wood from around the muzzle stopping at the back cut. He used the method of little flats to create an evenly rounded surface. Using a chisel, he cleaned up the back edge.
(https://i.ibb.co/VmtP5pw/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/C2zTDsP)
(https://i.ibb.co/DYWMdqw/OLYMPUS-DIGITAL-CAMERA.jpg) (https://imgbb.com/)
(https://i.ibb.co/0CsqVx5/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/rxdkfV9)
(https://i.ibb.co/47kkGgk/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/Y3ggMTg)
I cut and annealed some sheet brass, which he bent around the muzzle using the shaped wood as a form. We finished the bending process by attaching 2 hose clamps and tightening them down. The result was perfect.
(https://i.ibb.co/BP1qNRx/OLYMPUS-DIGITAL-CAMERA.jpg) (https://imgbb.com/)
(https://i.ibb.co/tcLdJCR/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/MpBXCNd)
After bending the sheet. I had Josh trace the inside profile of the cap on a thicker piece of brass that will form the front. I cut and filed the front to that scribed profile and soldered it inside the front of the cap. To speed things up a bit, I cut and filed the profile of the barrel muzzle into the front of the cap and Josh and I final fitted it to the stock.
(https://i.ibb.co/4M8WPqd/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/HYt7nSd)
Finally, he pared more wood down on the fore stock so it was near flush with the muzzle cap and we cut the ramrod channel moldings. I marked lines on the stock and using an old marking gauge, scribed a line in the wood. I use a coarse checkering tool to deepen that line and then a dog leg chisel to relieve back ground wood along that line creating a raised shoulder. It takes about 20 minutes per side to do. Since Josh could now feel and use that shoulder as a guide or fence, I had him clean up the background with the dog leg chisel, bottoming file, and straight Japanese rasp with safed edges. He did a good job. There are a few spots I will clean up but it will look crisp and straight when we are finished.
(https://i.ibb.co/2cbkMQP/OLYMPUS-DIGITAL-CAMERA.jpg) (https://imgbb.com/)
(https://i.ibb.co/XS1YTpf/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/f4fD7tV)
(https://i.ibb.co/hyJ1Q41/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/47ngvXg)
Well that was it for a couple long days of work. We worked pretty late yesterday and when the sun was brewing up a nice sunset
(https://i.ibb.co/kJ5svrk/OLYMPUS-DIGITAL-CAMERA.jpg) (https://imgbb.com/)
we figured it was time to drive Josh back to where he meets his wife to go home in Rutland.
dave
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Wow - well done, Dave.
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Amazing stuff! :)
Curtis
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It truly is. Great job!!! :)
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Hi,
We got more done last Saturday. It was time to make and install a side plate. I modeled one from a 1770s vintage Lancaster gun and used an old cast English plate as the raw material. I cut out and filed the outline and then had Josh clean up the edges and file the bevel. He did a great job with the task.
(https://i.ibb.co/dgBzH3m/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/vY1KMrX)
I decided to let Josh outline the mortice for the side plate because the thick brass gave him a nice edge to feel. So Josh screwed the plate in place and used a razor sharp knife with a pointed tip to trace the plate.
(https://i.ibb.co/4dy4R3w/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/HdvGT3L)
He did OK but he tended to put too much pressure on the knife such that it cut deep and caught wood grain that led the tip astray. He did not grasp my direction to use a light touch because all he was doing was scribing the outline. We deepened it by stabbing in after marking it. Anyway, the stock will have a few scratches around the plate after finish but they won't show very much. I corrected and cut the outline and back cut to create an edge to the mortice that Josh could feel. He removed the background.
(https://i.ibb.co/vmHjB2T/OLYMPUS-DIGITAL-CAMERA.jpg) (https://imgbb.com/)
The inlet came out great. There are a few tiny gaps but they will disappear when the wood is stained and finished. I want to emphasize how difficult this is. When using a chisel, he has to have his hand on the tool but low enough near the blade so he can use his pinky to feel where it is going. Then he has to tap the chisel with his other hand. He tends to position the chisel at the right angle but when he gets ready to tap it, he unconsciously lowers the angle of the chisel so it skips over the wood. He has to consciously raise the end of the tool before every tap. Acer had an idea that Josh may do better if, rather than a mallet, he hits the chisel with a flat weight in his hand. It may give him one less thing to think about.
(https://i.ibb.co/s34rcqP/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/7yDFBKz)
The rest of the day was shaping the stock further. Josh did well but as we get closer to the finished product it is clear that I have to do more of the work. There are subtle details that he cannot perceive but we will try to push his capabilities as far as we can. Here is where we are and you can see minor gaps in the inletting and some imprecision in shaping, but most of that will disappear in the final form and Josh has done a remarkable job.
(https://i.ibb.co/XjPZzY0/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/0mLjfs4)
(https://i.ibb.co/dmh10Vq/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/2Zbm7CQ)
(https://i.ibb.co/7KCNbhC/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/ZxX1N9X)
(https://i.ibb.co/2sWSkDf/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/WPG02bY)
I communicate all your responses to Josh and he appreciates the support a great deal. Thank you all for looking and commenting.
dave
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Go Josh!
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Fantastic job - especially the in-letting. That in itself can be tricky and difficult to do. I think the more the final shape comes around, he will feel his way through the areas that are high, low and "rough". sort of like us using different light angles to see shapes that need adjustments, he feels them.
Wonderful work.
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That is amazing. And incredible. And whatever else great you can think of. I cannot scratch the surface of what he is doing. Please pass along my compliments. God Bless, Marc
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A great project and by the looks of his smile I would say he is a very happy builder. Very well done Sir.
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This is turning into a piece to cherish forever. Remarkable skill and persistence by both Josh and yourself to tackle this. Keep up the good work.
Mike
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I agree with these other builders, incredible job. You should both be very proud of your accomplishment.
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Can you imagine the feeling when he shows this rifle to folks and says, "I built this" ?
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Can you imagine the feeling when he shows this rifle to folks and says, "I built this" ?
I think his face may crack from smiling so big when he does.
Mike
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Josh has certainly done an outstanding job. Please convey my congratulations to him. And a thank you to you, Dave, for being a mentor to him. Both of you are to be commended in the building of this rifle which I'm sure Josh will cherish forever.
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Truly, this is one of the most inspirational and heartwarming threads I have ever read here.
Ez
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Hi Guys,
Thanks for looking and commenting. We got more done. A very special tool came from the mind and generosity of Acer (Tom Curran). He suggested that Josh might have an easier time tapping a chisel if he used a flat weight in his hand rather than a mallet. It might make it easier for him to concentrate on the tip of the chisel rather than connecting the mallet and the chisel handle. Instead of just making the suggestion, Tom sent a thick steel disk that he turned. It worked like magic with results you can see below. Tom, it was a brilliant idea and it made a difference immediately. We got the trigger guard inlet and Josh did most of that and we installed a toe plate, which Josh inlet. The toe plate was one I made for my first rifle back in 1978. It was simple but appropriate so we used it. We installed the trigger and adjusted it to about 2.5 pounds for now. After tuning and polishing the lock it will get lighter but we have to consider safety. Josh has to feel for the trigger so we may not want it too light. Here is where we are. We need to do the final finish shaping, carving, and inlet a patch box and star in the cheek piece. The patch box will be the famous "tulip" box by Dickert shown in RCA 1. I think you can see what a handsome rifle this will be. More to come.
dave
(https://i.ibb.co/0mRW3Sj/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/Cm3XFZ5)
(https://i.ibb.co/ZGM8wwJ/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/jbrMxx5)
(https://i.ibb.co/JmS04Wn/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/NtGQPgx)
(https://i.ibb.co/6rMBzkB/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/Gn6TyqT)
(https://i.ibb.co/Z6w9SV2/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/3y8Kv7R)
(https://i.ibb.co/mvkBb03/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/YDmWPXx)
(https://i.ibb.co/ZcVLp70/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/ygXfc7r)
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Blind or not, that is some really fine work. The both of you need huge congratulations on this project.
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Thanks Craig,
I'll pass the encouragement on to Josh. Thinking about the toe plate from my first gun, let me entertain you all with a little story. I was very close to my Dad. We made things in his shop since I was 8 or 9 years old. Pop could make anything and had extensive knowledge of basic wood and metal work. When he retired in 1977, he took up wood carving with a passion. He was very skilled with the tools and techniques but he was never an artist. He was a craftsman. His carving was the typical work of old retired guys, the "cowboy boot", the "grumpy face in the walking stick", carousel horses (although dad did do a great carousel pig with wings), and wildlife. Since I worked with canids, including foxes, coyotes, and wolves, Dad carved lots of them. I loved them but they all kind of looked like chubby labs with erect ears. No matter, they were great. I got into making muzzleloaders because a friend took Dad and I out to shoot his TC Hawken. This was 1976. We had great fun but both of us looked at the rifle and concluded that we could build a better gun. So I went to the library looking up books about old guns and decided flintlocks long rifles were for me. My guiding book was Kaufmann's "Pennsylvania-Kentucky Rifle", which I bought and devoured. With Pop's support I ordered parts from a newly discovered Dixie Gun Works, which included a Siler flintlock kit, rough stock blank, Douglas barrel, a few parts and McCory's little book on Kentucky rifle building. We went from there making all the other parts like ramrod pipes, patch box, sights, barrel lugs, muzzle cap, side plate, cheek star, barrel pin escutcheon plates, and toe plate all from scratch. I learned a lot about locks from building that kit. It was also the perfect vehicle for Dad to remember his technical training in metal work and teach me all of those pre-World War 2 secrets. Well, we built the gun together and it came out well but with many of the pitfalls of those who have not handled originals. Regardless, when it came to designing carving and inlays, the only really inspiration from my Dad was the rounded arrow head, which you see in the toe plate on Josh's rifle. If I ever asked Dad for ideas, that was the only thing he would suggest. It was safe, symmetrical, easy to make, and bland. I was bored by it and wanted more but that ability came later. Pop sent me on the road in many ways and using that toe plate on Josh's rifle is very appropriate. Dad would approve.
dave
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Much respect Dave. Says alot....
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It only looks a couple hundred percent better than my first couple of gun builds. And I can see, at least I think ;) Amazing job. Dave your tutelage is to be more than commended. BJH
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There are other ways to be a Hero Member on this site, but that's got to be the best. I'm guessing Josh thinks so too.
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Golly, Dave, this is so heartwarming. I'm glad to see the short mallet is handy. If Josh needs a smaller one, let me know.
This impressive work by Josh says a whole lot about him as a man, and a whole lot more about you, Dave. Wow, just amazing.
Tom
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Hi,
We got more done. Josh helped me make and install a brass patch box with spring catch mechanism. To be honest, I did most of the work but he helped file and shape the patch box finial and side plates as well as prepare the surface of the stock to receive the box.
(https://i.ibb.co/GFRYDQz/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/BwBWJ20)
(https://i.ibb.co/wz1QTXk/OLYMPUS-DIGITAL-CAMERA.jpg) (https://ibb.co/Tg50ZSf)
(https://i.ibb.co/gTSCMKq/OLYMPUS-DIGITAL-CAMERA.jpg) (https://imgbb.com/)
The design is a copy of one attributed to Jacob Dickert. Only the box survived from that gun and it is one of the best Dickert made or used. The finial is a tulip and the whole box will be engraved folk art. Josh had a very special teacher who helped him a great deal and loved tulips. I mentioned that many Lancaster guns had daisy patch boxes so one shaped as a tulip would not be out of place. Lo and behold, we found the Dickert "tulip" box and chose that. We still need to clean it up a bit as well as the hinge but it came out really nice and is one of the most charming patch boxes I've seen. Josh will eventually cut and clean out the rest of the patch box cavity. Next up is carving.
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I continue to be amazed at the two of you, Dave.
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Josh and Dave you have knocked this project out of the hollar.... It is so heart warming. Josh has to be commended for doing what it takes to overcome his adversity. Dave you also need to be commended for the assistance you have given Josh to overcome his adversity.
You will both walk away with a wealth of knowledge and experience that most will never experience or know. It will be one that you will keep close to the heart and a friendship that I am sure will last til the end of time.
I can imagine that there will be a legacy from this build as there is no other I imagine.
Thank to both of you for sharing a part of your lives with us. Thank you.
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I know this is a really good thread. But i just gotta know how it turned out! Such a cool story!!
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Hi Hutch,
Thanks for looking. Here is how it ended up.
https://americanlongrifles.org/forum/index.php?topic=62908.msg630960#msg630960
dave