Bill_in_fl,
I applaud you efforts so far and envy you having the fun project.
I have had success rounding out the bottom of the sight base and soldering directly to the curved barrel surface. You have already removed the nickel plating and you wouldn't have to mill the barrel.
Actually with the sight taped securely in place I would always shoot it at this point to check for proper sight height. I would hate for the sight to be too low or to have to file thru the nickel plating on the top of the sight blade if it's too high. I always prefer to make my adjustments to the bottom of the sight base.
Just some thoughts and I enjoy following your progress.
Thanks Hondo. I have previously given what you mentioned consideration. I did not remove the nickel plating off the front sight though. But since the front sight was cut off of its previously nickeled barrel, the very bottom side of the sight isn't nickeled. Just its top and sides.
I also thought about just curving the bottom of the front sight so that its curve matched the curve of the barrel and then soldering it onto the barrel rather than using the option of milling a flat on the barrel as was previously done on JacktheToad's barrel that I got the sight off of. That is an option and I might still do that.
I had also thought about that problem and you're right about not having to file the sight once it is installed and making sure it is the proper height when installed and to take any material off the bottom of the front sight rather than the top.
There are several things I thought about doing to make sure the front sight was properly aligned both for windage and elevation.
My first idea was to place the revolver in a vice and make sure the rear sight groove and barrel were perfectly level by using a bubble level or laser level on it. Then along with that, I thought about placing a wire suspended also perfectly level and horizontally attached tightly between two screws in wood....over the very top of the rear sight groove where the tip of the front sight should be seen.
Then keeping the leveled wire at the top of also leveled rear sight groove, I would see if the tip of the front sight blade would just barely touch the underside of said leveled wire. I theorize that should give me the correct height.
There are several variables to consider.
1. What if the revolver did not shoot to point of aim to begin with? Since it didn't have a sight on it when I received it, I don't know. Then my aligning the sights like I described above wouldn't make any difference.
2. If I milled a flat into the barrel for the sight to sit in and be soldered in, would that make my front sight too low? I could check that with leveling the sights and barrel with the level wire, but again...what if it didn't shoot to point of aim to begin with?
3. If I just curved the bottom of the front sight so that it matched the curve of the barrel, with the thought of then measuring its height using the leveled barrel and leveled rear sight groove and leveled wire as I described above, even if I got the sight the perfect height without milling a flat into the barrel, how do I know it would shoot to point of aim without knowing if it did so before?
Hondo, it would be a good idea for me to temporarily tape/attach/superglue the sight (or a front sight blade proxy and not the actual sight) and try shooting it to see if it shoots to point of aim. If I temporarily attached and used a front sight proxy (instead of the actual half moon sight I would install later), then I could bench rest shoot it and adjust the height of the proxy sight until I hit to point of aim at the yardage I wanted. Then I could measure the height of the proxy sight once I got it to hitting at point of aim, and that way make sure that if I measured how deep the flat would be that I could mill onto the barrel, that the half moon front sight would still sit up high enough to replicate the same point of aim that the proxy sight did. If after measuring and taking into account how deep the flat on the barrel would be, if the half moon sight would not be high enough sitting in that flat, then I'd know that instead of milling a flat, I should just curve the bottom of the sight to contour to the barrel's curve. And hopefully that would be high enough.
I hope I wrote all that so it was clear enough for everyone could understand what I meant.
A bit tricky and a sticky wicket getting this aligned.
Any other suggestions that might be a better option of doing it?
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