The 4566TSWSSV project

[BMCM]

Or maybe we can call it the 4596 Tactical

It's no secret I get a lot of enjoyment from turning an old beater into something nice therefore here we go.

So sometime last year I got hold of this beater 4566TSW. No box etc., one magazine and lots of MIM. This one had a rail on it at one time which had been removed and the holes plugged with aluminum rivets, one of which was missing. It looked a mess. Perfect says me, I brought it home.

Now, earlier this summer I managed to win two different 4513TSW complete parts sets.

Being that I'm an enterprising young lad who is somewhat enamored with the whole 4596 idea and having all these spare bits about. I figured I'll just make one of my very own

Here it is the last time it wore the 4.25" slide.

First order of business is to get the checkering sorted out. As you can see in the picture above, typical production line machine cut checkering isn't all that pretty.

So, out come the files again.

There, that's better.

I've picked out the best fitting slide and machined it to fit a spring loaded decock only lever.

And done.

Now taking that slide and using the barrel with the best lockup I blended the slide to the frame at the rear so they're perfectly flush. Yup we're gonna go with forged & flash chromed bits for this one.

I've also bobbed the beavertail by about a quarter inch. A tad more comfortable for me and lets me get a bit higher grip.

That's all for now

Cheers
Bill

 

[BrianE]

That's awesome.. can't wait for updates and the final product. I love following your projects...

 

[Derosa]

SuhSweet..I love it when a machinist or tool maker or craftsman displays samples of what can be done wit a bit of sweat and effort. Keep us informed with more pictures. Please.

 

[03Fatboy]

As usual, very nice work. Love to read about your projects.

 

[18DAI]

That is gonna be one sweet carry 45!

PLEASE hang out a shingle! I've got lots of work for you!

I will be following this thread with interest! Best regards, 18DAI

 

[Zebulon]

Agreed.....You have become the SW DreamMaker.........4566/4596...None better. Zebulon

 

[Gunhacker]

That is gonna be one sweet carry 45!

PLEASE hang out a shingle! I've got lots of work for you!

I will be following this thread with interest! Best regards, 18DAI

The trouble is... once the word gets out that he's hung out the shingle, there will be a year turnaround time for each of your projects, due to the massive backlog that will surely develop. I gots some dream guns ideas too!!

 

[4506517]

YES!YES!YES!YES!

I LOVE THESE THREADS!!!!!

Do we have an eating popcorn icon?

<------------

 

[D Rock]

Great work, thanks for the pictures.

Dave

 

[presspics]

Is it done yet???? I want to see it done!!!

 

[BMCM]

Getting the recoil spring arrangement sorted out today.
I've been very pleased with how well my 4516-1 functions since I fitted it with a custom guiderod & flatwire spring so, I'm going to to the same with this gun.

In December last year I shortened and polished a CHP guiderod for my 4516-1 that used the original single spring. Well that guiderod went back in the parts bucket when I switched over to a flatwire.

Today that same guiderod received a new lease on life when it got spun up in the chuck for a little adjusting.

Relatively simple job. I just needed to reduce the diameter from .290" down to .250" clean up any tool marks and polish.
I was about halfway done when I remembered to get the dang camera So here we are at the cleaning up the toolmarks stage. Got a strip of 600 grit abrasive tape there and the part is spinning at about 550 rpm.

Had to stop the machine a flip the part a few times to make sure I got full coverage then hit with a some Simichrome on a clean shop rag.

And... We're done

Just for comparison. Top is a 4013TSW rod (I think), Middle I just finished and bottom is a solid stainless 4566 rod.

Also needed to open up the hole in the spring tunnel a few thousandths to accommodate the fatter guiderod. You can see also I've been easing some of the sharp edges up there too.

Ok lets see how it looks when we slap it all together.

Yup, good from this angle.

How about up front?

Ya, das ist gut.

And, should the need ever arise, we're still backward compatible with the nested springs.

I'll probably do some more fiddling with the dust cover later in the week.

Boy, I sure hope my welder gets back from the shop soon

Cheers
Bill

 

[Zebulon]

"when we slap it all together..." You're a funny man Bill. Gifted, but funny.......Zebulon

 

[bgrone]

Good work

Once again I am awed by your workmanship,keep sending pics.

 

[wlp624]

Hot Damn Boats! Uh, I mean Master Chief. We're off on another Great Adventure!

 

[4506517]

Again I am in amazement of your skill. You make it look soooo easy......that is the hallmark of a true expert.

It would be awesome if you did take on work. Think about it....you're really the only person who does this kind of work to 3rd gennies. I can understand why you don't though.....we would inundate you with so much work it would cease to be enjoyable.

Please continue with the threads. They truly are the highlight of the semi auto section.

 

[BMCM]

Thanks guys for all the compliments

I often entertain the possibility of taking on some outside work.
The off putting thing is all the nonsense one has to go through to do this legally.

State business license
County permit
City permit
Federal licensing
And... let us not forget Liability insurance
Plus whatever other stuff I haven't thought of or hasn't occurred to me yet.

From what I understand the Fed Licensing is the easiest part.

And dealing with bureaucrats gives me heartburn.

Just the mere thought of having to beg permission from some deskbound bureaucratic jackwagon who demands a portion of the fruits of my labor in compensation for granting me permission to do the things I like to do makes blood shoot from my eyes.

I'll take another look at this after the Holidays. If I can clear all the legal hurdles without to much pain or having my head explode maybe we can get something going here. I'd be more than happy to take on some projects for you folks.

Stay tuned

Cheers
Bill

 

[BMCM]

In contemplating the beavertail, I thought there was still a bit of room for improvement so... Out to the shed for some coarse material removal with the 1 x 30 belt bench sander than back inside for a bit more file work.

Cleaning up and adjusting the contour.

And here we'll work it over with some crocus cloth. first the 240.

Then the 600 grit. Dang that's bright!

Ok, that will do just fine.

Feels pretty good & sets nice and low in my mitt

Over in the slide stop department, we did a little softening of the sharp edges and removed the parting lines left from the mold during manufacture. As you can see, the machining of the cross shaft on this particular part is really rough. When I come across another slide stop in better shape I'll probably replace this one.

Also a parting line over here right across the center of that little flat. I cleaned that up too. It was buggin' me

Now on to the dust cover. If you look carefully here you can see that the dust cover thickens a good deal starting about half an inch past the trigger guard all the way to forward end. I suspect this was intended to accommodate the scabbed on rail.
The one on the bottom is my rail free never drilled 4566TSW. On top is our donor frame for this endeavor.

I've already messed with it some. Thinned it about half way of whats needed to make the thing uniform height the full length. I'm going to hold up here until I've dealt with the holes.

Yeah, these here holes

So here's the plan. Sure I could patch 'em up with some JBweld or other some such goop. I could even bang some blackened aluminum rivets in there.
Nope we're after a more evolved solution. What I'm going to do is either source or make my own countersunk rivets of 410 stainless steel. drop them into the holes and weld the heads in place from the inside. Allow it to cool completely then weld the shanks on the outside. Again let it cool then hand file to the final contour. If everything goes as planned there should be no indication from the outside that there were ever any holes there at all

Until next time...

Cheers
Bill

 

[timn8er]

Bill, I like that idea you have for filling in the holes. Sounds like it will work out nice. Can't wait to see it!

 

[J. W.]

Outstanding work, sir! I will be eagerly awaiting your next update!


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[Arik]

Ok, my honest opinion is that it looks like a train wreck.




Just finish it up and send it to me so people won't laugh at you

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