CLA/ALR Auction Rifle

[tallbear]

  Back in August the moderators on the ALR were asked if they would be willing to build a gun for the CLA auction for August 2012.This would be a project to promote both the ALR and the CLA.We moderators agreed that this would be a worthy project.Since distance between us and time was a factor it was decided that one moderator would be selected to be the lead builder.I was honored to be asked to be that builder.The other moderators would help where they could with polishing parts,supplying materials ideas and moral support.
  The theme for the auction is the war of 1812.A bunch of different styles of rifles were discussed and it was decided to build a Dickert/Lancaster styled rifle.One that could possibly be carried during the War of 1812.I thought it would be neat to take some pics as I progressed and maybee do a couple of tutorials as I built the rifle.
  I also wanted to thank the vendors who donated parts for this rifle.Their support of the ALR,CLA and this rifle is most appreciated and I hope you will keep them in mind when you plan your projects.
  Stock;Dunlap Woodcrafts
  Barrel;Getz Barrels
  Lock;Jim Chambers Flintlocks
  Hardware;Reaves Goehring
  Barrel/RR inlet;Mark Wheland 
 
Here is the stock,barrel and pattern ready to be sent to Mark Wheland for the barrel inlet.I made the pattern buy blowing up a photo of the rifle to a known number and then gluing it onto a piece of 1/8" plywood.This is a quick and easy way to make a pattern and is durable enough for several guns.
 



I will be glad to answer any questions you might have as I progress

 Mitch Yates

[Flinter]

If everything works out OK, my wife and I are planning on going to the CLA show or event. Can you tell me what caliber and barrel length this will be?

[tallbear]

BARREL LUGS
The first thing I do after getting the barrel inlet in install the barrel lugs.I do this by cutting a small notch .025 thousandths and then peeling up the dovetails with a chisel.This is a fast and period correct method of installing barrel lugs.I use commercially available lugs which are usually ¾ of an inch in length. I cut these  in half to make the lug 3/8” in length.

These are the basic  tools I use to install my lugs.A chisel to peel up the dovetail and a small fuller to push it back down on the lug when finished.




I then paint both sides of the barrel with a magic marker and scribe a line at .025 depth.Then using a hacksaw and a  pillar file I cut a notch like this one just a little narrower than the lug and no more than .025 deep.



Then using the cold chisel I peel up the lugs on both sides until the lug slips in .







Then using the fuller I push down the metal that I peeled up to lock the lug in place.





Once the lug is locked in place you clean it up and inlet.No solder is necessary and you haven’t notched any deeper than .025.





Glad to answer any ?’s
Mitch Yates

[tallbear]

Flinter
The barrel is 45 1/2 " .50 cal.It was made by John Getz.

Mitch

[Tom Currie]

Mitch, Great project and thanks for posting progress. Your post is timely for me. Usually I file in the undercut notches on underlugs but am ready to use an upsetting tool for the first time. What kind of angle is on the cut out part of the barrel before using the upsetting tool ? I am assuming it not just square but maybe I'm wrong. Thanks

[tallbear]

Tom
It is square.I do hit both sides just lightly with a safe 3 cornered file.This makes an ever so slight groove to be sure the chisel is in the bottom of the notch.

Mitch

[tallbear]

Barrel inlet,RR hole (by Mark Wheland)and the tang inlet.


Lock nicely polished by Rich Pierce and slightly modified and inlet by me.
Buttplate installed




Mitch Yates

[rich pierce]

Keep it coming!  Can't wait for the patchbox!

[Dr. Tim-Boone]

Oh, yeah it is coming to life!

[Al Lapp]

I find this extremely interesting. Will be following this project for sure.   Al

[Jim Kibler]

This is a wonderful contribution all those involved are making.  Thank you.  It will be good to follow your progress here. 

Thanks,
Jim

[Bob Mac]

Mitch, will this rifle show up at Lewisburg? Sort of a work in progress for those of us who are there to drool over.
Bob

[Acer Saccharum]

She sure has a big butt.

[tallbear]

Thanks Guys.

The rifle will be on my table at Lewisberg.Please stop by and see me

She sure has a big butt.

No worries Acer she has been a a bit of a diet and is getting slimmer by the day

Mitch

[M Tornichio]

I love following along with builds.
I am glad you are taking the time to document the build as it come along.
Marc

[omark]

She sure has a big butt.

so does mine, but i love her just the same.   course that doesnt mean i cant admire smaller ones as well.         oh!   i see what you mean now.     

[tallbear]

Well it stoppd raining enough this morning to snap a couple of more pics.As you can see she is starting to slim down some

[tallbear]

Here's a preview of the patchbox

[Acer Saccharum]

It looks like your bed is outside. Do you sleep in the rain, big bear?

[tallbear]

No but if my wife finds out I swiped her table cloth I might be

Mitch

[JTR]

Awwww, the Dickert rattlesnake box!
Very fitting!
John

[B Shipman]

Great project. I'm dying to see it.

[tallbear]

Here is a quick pictorial of the patch box being done.I first make a paper pattern and glue it on poster board,then I form and fit the hinge of the patchbox.If I am copying an original I make sure the knuckles are laid out the same.

Then using the pattern I scribe it onto the patchbox and cut it out with a jewelers saw.Then it is cleaned up with files.

Patch box is ready to be inlet.Notice the hooks on the top of the two sideplates.These go under the hinge and secure the top of the sideplates.This is a feature of Dickert patchboxes.




Finial ready to inlet

Finial inlet

Side plates ready to inlet


This photo shows how I inlet.I scribe around the side plate with a xacto knife.I then stamp around it with small chisels. I then drill a series if hole 1/16” deep.These act as a depth gauge when cleaning out the mortise.

Fancy drill stop.


Patch box almost done.Just needs some cleanup and polishing and it’s ready for engraving
.

[Greg S Day]

Tallbear

Love the drill stop idea!

I was scrolling down through the photos and saw the depth indicator holes all drilled so nice.  I thought "right",  I'd be drilling at so many various depths.  Then I saw the next photo showing the stop.

A forehead slapper for sure.


Thanks

Greg
 

[brobb]

Tallbear

Thank you for posting this project.  I am enjoying your excellent pictures. Would you care to give us your technique for forming the square corner on the hook bend of the patchbox sideplates?  This is something that I find to be difficult to do.

Bruce Robb