A while back I came across a 25-5 with a 8 3/8 barrel. Pretty nice looking in the wood presentation box that lining was a bit beat. Gun was wearing really nice looking targets. But, as it was a pinned barrel gun I checked it with calibers and almost .458 throats. But, I bought it at a decent price of $700.
First not a fan of 8 3/8 barrels and the throats were not going to cut it. But having a couple other 45 barrels and a brand new never fitted early recessed model 29 cylinder ($100 off Ebay) I went to work. Removed the barrel and took it to the lathe. Cut it a bit over 5" and reinstalled the ramp.
I do that by removing old ramp from cut off barrel and then machine it in mill till only the ramp and blade is left. Then mill a shallow slot just deeper than the grooves in rib, the width and slight longer than the ramp. I clean up the corners of the slot with a 1/16" endmill so it is almost totally square then give that part of the ramps corners a tiny radius so everything fits very snug. Then I tin the ramp base and slot with a thin layer of silver solder. I use a small C clamp to press the ramp into position in the slot and heat it up again until the solder melts and a tiny bit comes out in the joints. The flux I use does not remove blueing. The solder melts at about 450 f and that temp doesn't harm barrel, but I do remove the insert as it would melt. I then clean up the bit of solder that comes out with small brass scrapers. Sight looks original that way. I leave the muzzle just a bit long until the sight is back on. Then I put the barrel back in the lathe. I have made a couple rounds of 2" brass that have holes tapped in center. One for N frame threads and another for K frames. By using these in the chuck and tightening the barrels into them it is easy to get them mounted in the lathe right and not damage finish. Then I final cut the muzzle and radius like original. Finishing with a brass ball lap and another that is an inverted.
Then I fitted the new recessed cylinder after reaming it to 45 colt. As the rims of 45 colt and 44 mags are the same the recess is no problem although my reamer would cut it. But this cylinder already had the correct recess. I ream in my mill with brass covers on the vise and use a old cut off extractor rod and a small washer to hold the ratchet firmly in place while reaming along with fired cases in some holes. I have a dummy spud that is turned to tightly fit 44 chambers and use it to perfectly align each chamber before reaming. My mill has a 3 phase motor and a Variable feed drive, so I can set it to turn very slowly when reaming. Clean and oil each chamber repeatedly as I ream it. Fit the ratchet for head space, then slowly filed and fit to time right. Trimmed and fit barrel to .005 gap when installed. Cast a new insert and then a little cold blue on muzzle and here it is.
Pinned and recessed 25-5 with 5" barrel and proper throats in cylinder.
First not a fan of 8 3/8 barrels and the throats were not going to cut it. But having a couple other 45 barrels and a brand new never fitted early recessed model 29 cylinder ($100 off Ebay) I went to work. Removed the barrel and took it to the lathe. Cut it a bit over 5" and reinstalled the ramp.
I do that by removing old ramp from cut off barrel and then machine it in mill till only the ramp and blade is left. Then mill a shallow slot just deeper than the grooves in rib, the width and slight longer than the ramp. I clean up the corners of the slot with a 1/16" endmill so it is almost totally square then give that part of the ramps corners a tiny radius so everything fits very snug. Then I tin the ramp base and slot with a thin layer of silver solder. I use a small C clamp to press the ramp into position in the slot and heat it up again until the solder melts and a tiny bit comes out in the joints. The flux I use does not remove blueing. The solder melts at about 450 f and that temp doesn't harm barrel, but I do remove the insert as it would melt. I then clean up the bit of solder that comes out with small brass scrapers. Sight looks original that way. I leave the muzzle just a bit long until the sight is back on. Then I put the barrel back in the lathe. I have made a couple rounds of 2" brass that have holes tapped in center. One for N frame threads and another for K frames. By using these in the chuck and tightening the barrels into them it is easy to get them mounted in the lathe right and not damage finish. Then I final cut the muzzle and radius like original. Finishing with a brass ball lap and another that is an inverted.
Then I fitted the new recessed cylinder after reaming it to 45 colt. As the rims of 45 colt and 44 mags are the same the recess is no problem although my reamer would cut it. But this cylinder already had the correct recess. I ream in my mill with brass covers on the vise and use a old cut off extractor rod and a small washer to hold the ratchet firmly in place while reaming along with fired cases in some holes. I have a dummy spud that is turned to tightly fit 44 chambers and use it to perfectly align each chamber before reaming. My mill has a 3 phase motor and a Variable feed drive, so I can set it to turn very slowly when reaming. Clean and oil each chamber repeatedly as I ream it. Fit the ratchet for head space, then slowly filed and fit to time right. Trimmed and fit barrel to .005 gap when installed. Cast a new insert and then a little cold blue on muzzle and here it is.
Pinned and recessed 25-5 with 5" barrel and proper throats in cylinder.
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