Tips on making replacement inlays.

[Top Jaw]

Ordered a replacement side plate for an 1819 Harpers Ferry Rifle Im working on.  Of course it’s too big for the existing mortise.  Was hoping it would be closer.  I know I could clean it up and just inlet the new one to fit, and I realize a little inletting would be required even if it was a lot closer in shape.  However, I would rather adjust it to more closely fit the original existing shape, which is a little more streamlined and flows better than the one I ordered.  Plus I’d like to stay closer to the original shape. 

So....Are there some tricks or tips for making a pattern to replace a missing inlay?  Other than 97 try & trim attempts with some cardboard and an exacto blade?

[M. E. Pering]

If it were me, I would first fill the area of the inlet with modelling clay. Then take a piece of tracing paper and using the edge of a pencil lead to rub the edges of the inlay boundaries.  The reason for the clay is that it helps not distort the paper, an also helps the paper stay in place as you rub.  Fortunately, this inlay is not complex.

Matt

[Greg Pennell]

I’d try making a pencil rubbing, using an index card. Then cut your rubbing out, and try the fit...should be pretty close. Trim the card stock until you get the fit you want, glue it on a piece of brass, and cut out your new sideplate.

Greg

Edit: Matt and I must’ve been typing at the same time...good tip on the modeling clay, I never thought of that!

[Top Jaw]

Unfortunately I don’t think I can even use this boughten one to work from.  It’s gonna have one or two gaps too large to even hammer out and file back, I think.  So I’ll probably be making one from scratch.

[Top Jaw]

Well, I’ll have to give a buddy of mine some credit.  His idea was a hybrid of the two ideas already mentioned.  Which was to mash a piece of a styrofoam plate into the void to get an impression.  Worked like a charm.  I cut a piece of styrofoam plate, and used a wooden roller to compress it into the sideplate void.  Should be a perfect pattern.   

[rich pierce]

Nice trick!  You might try peening  the boughten sideplate to stretch it before making a new one.

[JTR]

Twere me, I'd do an internet search for an original one.
It'll no doubt cost more, but by far the best way to replace a missing part on a military gun is replacing it with an original piece.
John