Douglas used cold formed octagon steel, which was their downfall insofar as making muzzleloading barrels. When you shape
steel in this manner it can leave cracks in the outer shell of the steel. This can also happen in cold rolled steel, however, in
our method of making barrels using round stock, the barrel is always turned on a lathe after the initial hole is drilled in the stock. This is done to make it concentric around the bore, and in the case of making a swamped barrel, extra metal is removed before milling to shape. If the blank should have cracks in the outer shelll you can hear the "clicking" at the crack.
If the crack does not disappear in the turning process it is discarded. In the 37 years that we have been making barrels, we
have encountered it several times, and has not been a problem with our barrel making.
Back to those Douglas barrels. I built my first gun with a 7/8" Douglas straight barrel in 45 cal. It shot great, matter of
fact, I won the first match I ever entered, and I still have the gun. Unlike the individual who said about his first gun..."mine
was good enoough to sell"..........Don