Sorry for keeping you all in suspense.
I managed to get around the entry pipe area and moved on. I decided last week that I would install the touch hole liner and put on a front sight. I figured after all this futzing around and hard (enjoyable) work, That I wanted to hear the gun go BANG. So we shot it on Saturday with no problems. I'm still undecided on the rear sight, but we managed to put all 4 balls that we shot into a standard sized napkin stapled to a board at about 25 yards.
So. I've been fiddling around with blueing/browning metal scraps and finish sanding the stock, polishing the brass, etc. I happened to have the stock upside down in the vise, and stood back a ways. What's this I see? Looking down the fore stock from the muzzle end, the stock is crooked. I mean like a snake, crooked. Nobody noticed this on Saturday.
My stock blank is probably about 15 yrs old, so it should be pretty dry and stable. The off cuts from the side of my fore stock are still straight, so it wasn't internal stress in the wood.
What happened? When I installed the barrel lugs, I didn't check 'em with a straight edge. They "looked" straight enough. I can't help thinking that the lugs pushed/pulled that fragile eggshell stock this way. Yes, I inlet them into a centerline on the stock, but if they were a little off it would certainly put a little pressure on the wood. The barrel will go in or out easily, with no felt resistance.
Got any suggestions?