Most of my experience with S&W is with -2s, so I'll ask here. The smithing page doesn't seem right.

Anybody know how S&W cuts sideplates? I can't imagine what tool or process allows them to cut so precisely something that fits back in as if no tool ever touched it. Mind blowing.

P.S. Anybody surf Doc44s pics today in the masthead? Page after page of beautiful history.

They must use a heavy duty cookie cutter.

They must be done one at a time per gun since all side plates don't fit all guns. Seems like a manufacturing marvel to me.

Currently I "assume" it is with computerized machining. Back 50 years ago I don't know. Had to be some highly talented machinists.

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H Richard
SWCA1967 SWHF244

This is a w.a.g., but maybe they used a process similar to duplicating a car key. A cutting tool would follow the contour of a standard blank.

Do you think they cut the side plate from the frame blank it's [re]installed on, or was it a separate piece of steel that was laboriously fit into an area routed out of the frame? I think routing technology was available. Either way, it's an awesome piece of machining.

Was there ever a film made of a S&W being made? A factory documentary or training/ instructional film. Seems like many industries did that. Would not it be a cool find if one such existed?

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Halfway and one more step

It's probably different today with the availability of CNC machining, but in years past the frame was cut with a router type machine cutter.
The side plate was cut to near correct size, then hand fitted by a master fitter using files and stones.

After the plate was fitted, it was attached to the frame with special bolts and the frame and plate were polished as a unit to insure a perfectly level fit between the frame and plate, with tight joints.

This is why used, replacement side plates never fit correctly, if at all.
The joints will show bigger gaps and the plate will either sit above or below the level of the frame.
Even today replacement plates need factory hand fitting to fit correctly.

Today I expect that the frame and sideplate are cut by CNC machining centers. Prior to that from about 1930 on I would expect that a Tracer Mill was used. BTW, a Tracer mill has 2 heads, one a tracing head that follows a Master Pattern and the second a cutting head that does the work. Prior to about 1930 or so I would expect that work like this would have been done on cam controlled machines similar to that giant key cutter suggested by blackduece.

I mean to say earlier that I thought I had noticed metal 'grain' going in opposite directions on the frame and plate, and this would explain it. Maybe I saw polishing marks, still, very cool.

There is also a large hammer involved believe it or not. Even with all of the cnc machines the side plate is still fitted by hand. The tight fit is also the result of some very skilled grease buffers. Even with all of the automation and mim there is still quite a bit of skilled hand fitting involved with a revolver and a good fitter is still a prized employee.

A couple years ago a popular sporting magazine I think it was F&S sent two gun writers to The Browning factory in Japan for a tour of the Citori production line. I was amazed at the amount of hand work that is still done on those shotguns. I would not be surprised if the side plates of S&W's were still fit entirely by hand.

In the 1950's when I visited the factory frequently the sideplates were installed by 'fitters'.
They were not the same ones who assembled revolvers with a tray of parts on their bench.
Remain amazed at this late date at the skills they had.
Also remember the ladies who examined polished parts before they went to the assemblers. What eagle eyes!