Barrel shroud manufacturing process?

[Model29-26.5]

Any of the machinists here know how the shroud was formed?
I figure the frames were and still are cast.
How were the barrels made in the old days? Were they cast or are they turned, polished and other parts added?
The rifling?
Is this something any of the real metal shop machinist wiz members here have tried to replicate?
I have not visited the factor but I would certainly like to squeeze in a tour when I’m up in MA next time.
I did a little metal shop in school but that was nearly 40 years ago and very basic.
Any books on this around about general SW manufacture from start to finish?
Thanks

 

[shawn mccarver]

S&W revolver frames have always been forged. Here is a video of the S&W forge in operation.

[ame]https://www.youtube.com/watch?v=mF4ekcE3k94[/ame]

 

[Alk8944]

Like Shawn Said, S&Ws have always been forged, never cast! This includes the frames, barrels and other components. Some are machined from solid stock. I have to assume the shroud of the two-piece barrel system is forged also. Some components are made by the Metal Injection Molding (MIM) process like the hammers and triggers. MIM is not casting!

The forged components are finished by various machining processes. Cylinders are made by machining from round bar stock made to company specification.

The only major manufacturer that makes major components of their revolvers is Ruger!

 

[Truckman]

And the ejector rod shrouds would also be forged as a unit with the barrel if my understanding of the process is correct......Ben

 

[Hawg Rider]

S&W revolver frames have always been forged. Here is a video of the S&W forge in operation.

https://www.youtube.com/watch?v=mF4ekcE3k94

It's interesting to watch the revolver forging process, and then listen to the host discuss the very detailed S&W QC inspection steps. It appears from the Posts I've been reading about lately pointing out poor manufacturing and lack of QC control and inspection, that S&W is perhaps leaving out a couple of steps before they box and ship.

 

[stansdds]

Until recently, when S&W started using separate barrel, barrel shroud, and retainer on some revolver models, the barrel, ejector rod housing, sight rib, and front sight or at least the sight base were one forging, not separate pieces.

 

[shawn mccarver]

It's interesting to watch the revolver forging process, and then listen to the host discuss the very detailed S&W QC inspection steps. It appears from the Posts I've been reading about lately pointing out poor manufacturing and lack of QC control and inspection, that S&W is perhaps leaving out a couple of steps before they box and ship.

On the other hand, out of the thousands they send out, we read of a small number with alleged defects. I have never seen anything that convinces me that the ones we see posted on this and on other forums constitutes anything more than a tiny number of the total made.

 

[Truckman]

I have never seen anything that convinces me that the ones we see posted on this and on other forums constitutes anything more than a tiny number of the total made.

I agree...The squeaky wheel makes all the noise while the others roll silently along......Ben

 

[Model29-26.5]

Until recently, when S&W started using separate barrel, barrel shroud, and retainer on some revolver models, the barrel, ejector rod housing, sight rib, and front sight or at least the sight base were one forging, not separate pieces.

That’s all great until you want to change the front sight, and then it has to be milled off.
I’m a fan of the pinned front sight myself, but apart from that, the one piece barrel/shroud that is forged sounds good.
I need to research a bit about casting vs MiM injection.
Sounds similar to me? If metal is melted and mounded then what is the difference?? I would like to see how the rifling is done and how the cylinder fluting is done.

 

[GerSan69]

On the other hand, out of the thousands they send out, we read of a small number with alleged defects. I have never seen anything that convinces me that the ones we see posted on this and on other forums constitutes anything more than a tiny number of the total made.

I think you're right. I also think that we see more reports because we have a concentration of S&W buyers here - in other words, out of every 100 people on the forum, most if not all own at least one S&W, where out of 100 folks on the street, maybe zero or one own any firearm at all.

 

[scooter123]

It's interesting to watch the revolver forging process, and then listen to the host discuss the very detailed S&W QC inspection steps. It appears from the Posts I've been reading about lately pointing out poor manufacturing and lack of QC control and inspection, that S&W is perhaps leaving out a couple of steps before they box and ship.

Most don't realize it but during most of S&W's years of production the quality of the finished revolvers was pretty bad. Fact is that up to the 1960's S&W dealers were required to have in house gunsmith's that were trained by S&W and capable of repairing defects on factory new revolvers. The reason the old classic's we see work so well is due to all those gunsmith's fixing mistakes at the factory. Note, US Auto Manufacturing was just as bad.

On a positive note the US Auto Industry implemented Statistical Process Controls and one critical aspect of SPC is that Manufacturing Operations much be designed so they are not CAPABLE of producing out of specification components. I was in that first wave of Manufacturing Engineers and a real believer in this quality system. Today if you are supplying parts to any Auto manufacturer in the USA the maximum acceptance rate for out of spec parts is 1 in 1 million parts and GM has stated they prefer it be 1 in 5 million parts. You can only achieve this level of quality if your manufacturing process is designed and monitored to insure that a defective part cannot be made.

My part time employer currently has 6 Swiss Lathes running somewhat complex stainless steel pins for Stellantis at a rate of 5000 per week for the past 5 years without one single defective part in those 5 years. To get there we have pre-programmed tool changes in place and 30 piece samples are checked with a statistical Capability study of the critical dimensions every shift. As for the cost, it's one single person doing the checks as well as tending the machines so it's not that expensive. Concerning savings, when a process can only produce good parts you do not have any scrap except for the metal fines from the machines going out the back door. If you are making a part with 6 dollars of value and part thrown into a scrap bin is pretty costly, so savings are huge compared to the old Inspect and Pack quality systems in place for so much of the manufacturing history in the USA that dates back to when Sam Colt was just starting out.

 

[Narragansett]

Drop forging I believe