Barrel staples

[dakota1647819]

I have a barrel with an underlug  staple broken off flush with the barrel surface.
The remaining three staples have a square cross section and appear to be a square peg
put into a round hole or channel and staked with a narrow chisel. Any thoughts on how to remove the broken pieces?  And are these really square pegs in a round hole?

Your thoughts will be appreciated

thanks, Ken

[docone]

The staples are probably not in deeply. They are in effect blind rivets. About the depth of the angled portion of a drill bit.
The staple is set in the vacancy, then the metal is planished down to the staple.
So, you will have the walls planished to the shaft, and the opening planished down to the shaft. A strong fastening, and you will have to grind away the planished material to remove the piece.
Why did it snap in the first place?

[dakota1647819]

thanks for the info. I will smooth up the area and see what develops.
I have been unsuccessful obtaining clear pictures.

As to why it broke, well it was that way when I got the rifle. I my opinion, the staple was worked hardened by too much cold forming. A stress riser was created when the staple was staked to the barrel. Both ends of the staple was a brittle failure at the stake marks. This stable, nearest to the breach end probably failed quite sometime ago. I do believe it is the cause of the through crack in the forend wood at the adjacent staple/wedge.

thanks, ken

[Dave B]

I have an original barrel with the square under lug  tenons that came out. They used a cape chisel to raise the metal  for the staple to be placed and swedged down. I should think if you have a small cape chisel you could bump up the tab and the leg still in the barrel would fall out.



The strip of copper shows the length of the under cut section being 7/32" long under the bumped up section

[TMerkley]

Try a 1/8" drill bit at the same angle as the staple and you might be able to drill the metal out without getting into the Barrel.  At least you will have an opening with which to work.

[JTR]

The staples usually have little feet at the bottoms of the legs that fit into the recess made by the cape chisel. (like on Dave B stripe of copper) I don't think many had straight legs that went straight into the barrel.
I wouldn't try to drill anything, but instead do as Dave B suggests, and make a chisel that fits the original size, and try to bump up the original bit of metal. It's going to be thin and fragile, so don't try to bend it up any more than necessary.
Then make a new staple to match the original, put it in place, and gently tap down the tab with a flat punch.

John

[DaveM]

Good timing on this post for me as I also have an identical problem right now with one missing staple on an old rifle.  Looks just like the one in Dave B's photo.  John, your recommendation sounds good but it is hard to picture, especially the metal tab you refer to.

[JTR]

DaveM, by the metal tab I mean the small bit of barrel that the cape chisel will lift up, to make the cavity for the foot of the staple.
John

[DaveM]

John, thanks for the clarification, I think I understand - I never saw the process (of installation).  I'll give this a shot - I couldn't picture how the metal on each side would "give" without breaking (I assume give by a tiny amount).  It must give somewhat if they were installed by pressing down the tabs so that makes sense.  Thanks!

[JTR]

DaveM,
My camera isn't handy or I'd post a picture.
You're correct in that when you pound the chisel into the barrel to make the recess for the staple, it should just lift the metal up a bit, and not tear it out.
John  

[DaveM]

John, I worked on it tonight and luckily the recesses only had dirt in them, not metal as I thought.  I was able to quickly form a staple and got it successfully installed.  Thanks
Dave