Rookie attempt.

[LehighBrad]

Starting my first pistol build from a BLANK. I already cut out the rough outline of the pistol using an old CVA pistol as a template. My question is....what is the best way to go about cutting in the barrel channel?? I'm going to use a straight 13/16" octagon barrel. I think I can do it just using chisels, but man, that seems very time consuming and accident prone for a pistol rookie like me.

http://i1237.photobucket.com/albums/ff466/LehighBrad/0013_zps0fe722ff.jpg

[E.vonAschwege]

You can lay out the design of the pistol on the stock, and draw the barrel on.  If you have a drill press, you can set up the stock and drill down to a specific depth.  Hog out most of the waste up to that depth, but not including the sides.  Lay the barrel in and trace the profile (or use straight edges), then chisel away. I can find some photos of my process if you need.  Best,
-Eric 

[LehighBrad]

Thanks Eric for your quick reply....photos of the process would be GREATLY appreciated!! I do have a bench top heavy drill press, and a copy of Chuck Dixon's book "Building The Pennsylvania Longrifle" but having NEVER inletted an octagon barrel from scratch its illustations and instructions are, to me, vague. 

[PPatch]

Brad;

Since it is a fairly small pistol project how about doing a try-stock first so you can get the hang of chiseling that barrel channel and become familiar in what will be involved in shaping it? Just a thought - think of it as doing a life sized sized sketch.

dp

[Acer Saccharum]

This has beentalked about many times, inletting by hand. A search may prove fruitful.  Long John, for example, has presented his method in pretty good detail, as have others.

[SuperCracker]

for a straight octagon barrel it will be worth the time to make a scraper that is exactly the profile of your barrel.

[eddillon]

If you have enough wood on the sides of the proposed barrel channel. screw steel strips along a pencil line marking the sides of the barrel.  Using a back saw, cut down along the steel strips to the depth of the oblique flats.  Go to work with your chisels to remove the wood.   

[blaksmth]

If your barrel is too long and you have to cut it off you can make a scraper out of the excess and it will be  the right size

[rsells]

I purchased a set of octagon scrapers from Brownell's that work great for me.  I think they were about $25 for each size cutters including a handle, but I am not sure what they are now.  Each size has three rubber mounted cutters on a handle and makes a smooth cut when you pull it through a rough cut barrel grove.  A good tool to have.  You can rough in the channel and clean it up really well with the scraper.
                                                                            Roger Sells 

[Curtis]

These guys have given you some excellent advice.  It really isn't that difficult, just takes a little care and patience.  If Eric could post his pics maybe it would help you get started.  You could also look at Hoot Al's excellent site for inspiration.  http://www.hootalrifleshop.org/youth_jg_rifle.htm

Curtis

[gwill]

I'll second the comment about patience.  I'm building a half stock fowler and decided I wanted to experience inletting a barrel. The barrel is in now. It wasn't as hard as I thought but it took me a lot of time.  I'd encourage you to take your time and give it a try.

[LehighBrad]

Thanks fellas for all the replies....I do have access to one of those three bladed 13/16" octagon barrel channel scrapers from a friend, but since I hate borrowing peoples tools, I'll have to buy one myself.:-)  I mainly want to see how builders go about "hogging out" all the wood necessary to fit the barrel into the stock...mostly by hand if possible. I never was too crazy about using fast moving power equipment. I've screwed up many a wooden projects over the years with just a dremel!!!

[Bob Roller]

These scrapers can be made easily from Speed-bor"drills or a
similar product. Buy the size you need and grind off the pilot
point,grind the 45 degree angles and then heat and bend the shank to
what ever angle feels good to you.You can also put wooden handles
on these too.I have some that have unbent shanks that I used in a milling
machine that was run a maximum speed.Makes a great router,rigid and
accurate.

Bob Roller

[blaksmth]

 I have seen some original rifles that when the barrels were removed the only parts that really looked nice were the sides of the barrel inletting the part below the wood was poorly inletted and the nose cap on the end was made nicely to fit.

 I am not suggesting you do this but not all old gunsmiths were all that precise , and if you do get it too deep acra glass is a godsend for bedding, I am not suggesting but mistakes can be fixed by modern Glues.
When you start getting the barrel in the wood mark the sides with an X-acto knife blade and keep the edges of wood cut with this cut I donot use a pencil as it leaves too wide a line and  will make the channel too wide for me    Good luck and take your time

[Dave B]

I did an demo at a Rondy on inetting a barrel into a blank using just period tools. It took me all day Saturday to inlet the 42"swamped barrel.  I used a period brace and series of bits to drill the center line of the channel then use gouges to open up the space enough to then use my hand planes to shape out the inlet. I believe that was when I finally decided that I was never going to hand inlet my barrels ever again.

[Rich]

What I do is to lay the barrel on the stock where you want it and draw pencil lines to mark the sides. DO NOT cut on the pencil lines. They are only a really rough guide. About 1/8 inch inside of each line, remove enough wood so the the bottom 3 flats of the barrel will sink down enough so that you can accurately scribe the sides of the barrel. A sharp scribe or exacto knife blade will work. Don't try to scribe too deep, you'll lose accuracy. scribe just enough to see where the sides of the barrel are. Using a straight carving gouge/chisel, cut down just inside the scribe line with the bevel of the gouge towards the center of the barrel. Remove the wood to the depth of a little less than 1/2 of the side flat. (not 1/2 the barrel but 1/2 of the side flat.) You will end up with a rectangular groove the depth of a little less than 1/2 of the barrel flat. Smoke the bottom flat of the barrel to mark, on the bottom of the groove, the location and width of the bottom flat. Cut another rectangular groove. Use a square to find the proper depth. You will end up with a groove that is T shaped. Remove the two shelves to make the octagon channel. Then it's a matter of smoking the barrel and testing to make sure it is fully inlet. Be careful about scraping the sides. You want to keep a tight fit. Be patient.

[LehighBrad]

Work smarter...not harder. This barrel channel inletting system seems to be working pretty good for me!! Thanks again for all the helpful advice fellas!!