Ahhh Help!!

[cstjones1999]

I was replacing the front sight in my 627-0 with Meprolight night sights...which I have done about 4 times before with out a hitch. Well I drilled out the sight while in the barrel and the bit snapped off part way inside. The bit is flush with the far side of the barrel. I didn't have any more #54 bits at the time, so like an idiot I tried to push the bit out with the sight pin. Well, the end of the sight pin is flush with the left side but, it mushroomed ever so slightly and the partial bit is still in the other side. My front sight is rock solid and it doesn't look that bad, but it's not how it's supposed to be. I just got replacement cup tip punch and drill bits from Brownells today. The cup tip punch lasted 20 seconds and snapped like the fist one...$17.99 down the drain...besides shipping back to smith...any suggestions?

 

[john traveler]

Sorry to say, but your next most appropriate action is to take the disassembled action (without cylinder and grips) to a local machine shop that has Electronic Discharge Machining (EDM) capability.

They will make an electrode to match your #54 drill bit and burn out the broken drill bit and cross pin without damaging the barrel rib.

It's gonna cost a pretty penny though...

 

[scooter123]

Hate to say it but John's suggestion is the safest way. Too bad your not in Michigan, the parent company for Magnaport does EDM machining and I'm sure they would do a fine job.

Now, one possible alternative would be to purchase 2 additional punches and shorten one so that the tip is only about 1/8 inch long. The reason that this might work is that it's a lot more difficult to break a short column than it is a longer one. That shortened punch may be able to get that stuck drill bit moving, at which point it should back out more easily. Needless to say, you'll want to be very careful that you don't cause any cosmetic damage.

 

[m1gunner]

Working with just hand tools will be tough to get this done without additional damage.

If it were mine I would contact S&W, and talk to a smith if you can. They should be the safest and most cost efficient shop for the job.

Without a good fitting barrel vice and a precision drill press, I wouldn't even attempt it on one of my own. With those tools, I can think of several ways to proceed......