I have a Model 63 which I bought new in the mid 1990's. It recently started having issues which I determined were cause by a lengthwise split in the milled flat of the extractor barrel. I looked for tutorials on fitting a new extractor; youtube, Kuhnhausen, gun forums with no luck. With an assortment of small files, stones and an optical visor I proceeded anyway ... slowly filing, stoning, testing each lug in sequence until the job was done to my satisfaction. I embarrassed to say it probably took me 20 hours to complete this project. My question is what tools would a gunsmith/the factory use ie; jigs, custom files, etc. for an extractor replacement. I would guess a knowledgeable smith could the same job in about an hour. Thanks.

The factory uses...or used to use 4 inch barrette files to final fit extractor ratchets. Ratchet teeth are still pre-cut with a hardened hand fit to a trigger with a handle welded on for leverage.

Congratulations on your hand work.....final fitting an extractor is one of the most critical, tedious and difficult fitting jobs to do correctly.

__________________
Ret. LE, FA Instr, S&W Armorer

Nice work on fitting the model 63 extractor! The ratchet surfaces are so tiny to file and this really adds to the difficulty. I have experience working on my 63 no dash. When I originally purchased it used, it was out of carry up and the cylinder had tons of rotational play. First I installed an oversize cylinder stop and then a new hand that was wider and went to work equalizing the ratchet surfaces with my barrette file. Working off and on for days I finally got it right but it definately wasn't easy. One more thing that wasn't mentioned was the need to have and use a .22 caliber range rod to make sure the barrel cylinder alignment is correct. This definately should be done after any ratchet or cylinder stop work.

I did this job ONCE on my inherited Baby Chief's Special (when my Dad passed away). The gun (circa 1951 ) had been shot so much that 3 out of 5 shots did NOT go bang! That's how bad the timing was and an over sized Hand was not the answer.

Thankfully he also left me plenty of original parts so I did have those. It took me several hours to get the 5 Ratchets correct and I used miniature files along with very small Arkansas Stones to do this. While the Revolver now is in perfect time and everything turned out perfect, it was a P.I.T.A. task. Yes I'd do it again if I had to, but would not look forward to doing so.