L1A1Rocker
10-28-2010, 12:09 PM
Please forgive the constant disclaimer: Do not start your own silencer project without first obtaining the ATF Form 1 approval back in hand plus any state paperwork that may be required in your state. Silencers a legal in 30 some odd states - please stay legal.
Part 1 dealt with the barrel, this part will be the End caps, internals, and tube.
For those that read the Mauser build this may not be all that interesting as I'm duplicating that design here. The Mauser turned out scary quiet so it seemed logical to go with that design.
Sorry I did not think to take a picture or two before this one but I did remember to get a couple of doing the outside threads here. These are completely lathe cut (no cheating with taps or dies) and is the part of the endcap that the tube will screw onto. This endcap will be close to the chamber end located apx. 1.5 inches away from the barrel nut.
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0373.jpg
And another picture of the thread cutting. This is a VERY slow process. The first few cuts are done at 5 thousandths of an inch and toward the end of cutting done at only 1 thousandth of an inch at a time.
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0374.jpg
After threading the outside for the tube to screw onto the next step was to bore out the inside and thread it to screw onto the barrel.
I use drill bits to drill out the inside till it is close
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0375.jpg
And then finish the correct inside diameter with a boring bar.
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0376.jpg
When it came time to do the threading I cheated. I started with a boring bar and thread cutting bit but I finished it using a 13/16ths tap (same as a Ruger Mk II barrel thread) and the lathe to keep it in alignment.
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0377.jpg
And the almost finished endcap. It still needs to have the O.D. taken down to the the same as the tube and have the gas tube put through it some how. At this point I'm not sure how I'll pass the gas tube through.
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0378.jpg
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0379.jpg
Next was the other endcap. I did not take a lot of pictures of this one as the steps become repetitious. This endcap will contain two polyurethane baffles with a small expansion chamber between them. It is bored out as much as possible, threaded to screw into the tube and cut off from the round stock. Here's a few pics.
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0380.jpg
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0381.jpg
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0383.jpg
Now I need to make the tube support. This peace will screw onto the end of the barrel and keep the tube in alignment. Do to the job requirement of this peace the outside diameter is very critical. It needs to be as large as possible but still allow for the tube to slip over it.
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0384.jpg
Here it is ready for threading. The reason for the shoulder is for a set screw so it remains steady and never shifts inside the tube.
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0385.jpg
Threading now done (yep, I cheated on this one too) and it's ready to be cut from the round stock.
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0388.jpg
So here are the three peaces so far; the two endcaps and the tube support.
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0390.jpg
OK, what next? The TUBE. OK, I wanted this rifle to be rather rugged so I went with 316 Stainless. To have the correct length I calculated for, the tube needed to be cut to 15.5 inches. If you'll take a look at the head stock you'll notice that I've secured the tube from the inside. I had something happen on this project that has never happened to me before.
With the tube secured in the headstock from the outside it was working its way out of the chuck. I have know idea what was going on or why. It didn't matter how much, or how little pressure I put on the jaws the damn tube was slowly working its way forward out of the jaws. NOT a good thing to have happen. By securing it from the inside it stayed rock solid. Anyone have any ideas what was going on and how to stop it?
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0392.jpg
Sorry I did not think to take pics of threading the tube. Cutting stainless is a little nerve wracking for me - its very hard and VERY noisy when cutting, I actually needed hearing protection!
OK, this segment has gone much longer than I realized it would so I think I'll go ahead and stop this one for lunch. I'll post another segment later today but I'll leave this with a moch-up picture.
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0395.jpg
Some of you may notice the Mauser's baffle stack in the upper portion of the picture. I had those out for reference on this project.
OK, that's Part 2. Part 3 to come soon.
Part 1 dealt with the barrel, this part will be the End caps, internals, and tube.
For those that read the Mauser build this may not be all that interesting as I'm duplicating that design here. The Mauser turned out scary quiet so it seemed logical to go with that design.
Sorry I did not think to take a picture or two before this one but I did remember to get a couple of doing the outside threads here. These are completely lathe cut (no cheating with taps or dies) and is the part of the endcap that the tube will screw onto. This endcap will be close to the chamber end located apx. 1.5 inches away from the barrel nut.
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0373.jpg
And another picture of the thread cutting. This is a VERY slow process. The first few cuts are done at 5 thousandths of an inch and toward the end of cutting done at only 1 thousandth of an inch at a time.
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0374.jpg
After threading the outside for the tube to screw onto the next step was to bore out the inside and thread it to screw onto the barrel.
I use drill bits to drill out the inside till it is close
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0375.jpg
And then finish the correct inside diameter with a boring bar.
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0376.jpg
When it came time to do the threading I cheated. I started with a boring bar and thread cutting bit but I finished it using a 13/16ths tap (same as a Ruger Mk II barrel thread) and the lathe to keep it in alignment.
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0377.jpg
And the almost finished endcap. It still needs to have the O.D. taken down to the the same as the tube and have the gas tube put through it some how. At this point I'm not sure how I'll pass the gas tube through.
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0378.jpg
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0379.jpg
Next was the other endcap. I did not take a lot of pictures of this one as the steps become repetitious. This endcap will contain two polyurethane baffles with a small expansion chamber between them. It is bored out as much as possible, threaded to screw into the tube and cut off from the round stock. Here's a few pics.
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0380.jpg
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0381.jpg
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0383.jpg
Now I need to make the tube support. This peace will screw onto the end of the barrel and keep the tube in alignment. Do to the job requirement of this peace the outside diameter is very critical. It needs to be as large as possible but still allow for the tube to slip over it.
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0384.jpg
Here it is ready for threading. The reason for the shoulder is for a set screw so it remains steady and never shifts inside the tube.
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0385.jpg
Threading now done (yep, I cheated on this one too) and it's ready to be cut from the round stock.
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0388.jpg
So here are the three peaces so far; the two endcaps and the tube support.
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0390.jpg
OK, what next? The TUBE. OK, I wanted this rifle to be rather rugged so I went with 316 Stainless. To have the correct length I calculated for, the tube needed to be cut to 15.5 inches. If you'll take a look at the head stock you'll notice that I've secured the tube from the inside. I had something happen on this project that has never happened to me before.
With the tube secured in the headstock from the outside it was working its way out of the chuck. I have know idea what was going on or why. It didn't matter how much, or how little pressure I put on the jaws the damn tube was slowly working its way forward out of the jaws. NOT a good thing to have happen. By securing it from the inside it stayed rock solid. Anyone have any ideas what was going on and how to stop it?
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0392.jpg
Sorry I did not think to take pics of threading the tube. Cutting stainless is a little nerve wracking for me - its very hard and VERY noisy when cutting, I actually needed hearing protection!
OK, this segment has gone much longer than I realized it would so I think I'll go ahead and stop this one for lunch. I'll post another segment later today but I'll leave this with a moch-up picture.
http://i79.photobucket.com/albums/j154/L1A1Rocker/300%20Fireball%20project/HPIM0395.jpg
Some of you may notice the Mauser's baffle stack in the upper portion of the picture. I had those out for reference on this project.
OK, that's Part 2. Part 3 to come soon.