Glad no one was hurt. The gun sounds like a great candidate for a Smolt conversion!
What you describe sounds like a textbook fatigue failure in a thread.with a clean break as smooth and even as if you used a plasma cutter. The threaded part remained in the frame.
First, S&W has no right to keep your property if you want it back. They may want a signed waiver or something, but at the end of the day, S&W cannot keep your property. Clearly, assuming the ammo was not the problem (and I do not think it was), it was most likely an over-torqued barrel. My guess - they will offer you a Model 66 from current production. Do not be surprised if they ask you to pay a small amount of "difference" between the value of the Model 67 of that era (without defect) and their cost on the current Model 66. If they offer a "trade-up," feel free to negotiate on a different model, if they make something else you like.
The Police Department I was on would not buy stainless steel revolvers. Eventually stainless steel was approved for privately purchase revolvers especially since a Lieutenant wanted a Model 66 to carry on duty.... Add that to a batch of early stainless that may not have had the best tensile strength, a good bit of over torque
PS watch this video and you will get an idea how much torque it takes at between 3:45 and 4:15
PS watch this video and you will get an idea how much torque it takes at between 3:45 and 4:15
The whole video is an interesting look at what goes on building them
Cambering the chambers at 2:10
Installing a barrel 3:40-4:10
The jig at 4:20 4:20 to start trimming the barrel gap to the cylinder
The tool at 4:30 to cut the ratchet teeth
Cutting the forcing cone at 5:10
Checking the timing at 5:30
SorryIs there a link?
Cornball columnist Lew Grizzard wrote of stuffing a pistol under his butt. Something about the car seat and motion of the vehicle touched it off, wounding him in the rear. He said the company was very concerned and sympathetic, until they got him to send it in for examination, whereupon it became "what gun?"