How to Make a Barrel Band and Rear Sight Base

Barrel Band Fabrication

• 1

  Unload your weapon completely. Visually inspect the weapon to ensure that no live ammunition is present.

• 2

  Secure the weapon in a padded gun vise. Ensure that the portion of the barrel where you're going to position the band is accessible.

• 3

  Measure the circumference of the barrel in microns using a dial caliper. Add 1/64 inches to the measurements. Transfer your measurements to a piece of flat bar stock. Stencil the measurements onto the bar stock.

• 4

  Cut the bar stock -- using a mill -- down to a square or rectangular shape, large enough to encompass the diameter of the barrel and any other attributes it will be secured to. Ensure that you have at least 1/8 inch of metal outside of the stenciled radius. If you are making a band for a single contoured barrel, you will need to cut the bar stock to a square shape. If you're attaching the band to a lever-action rifle with the magazine tube included, the bar stock will need to be a rectangular shaped to encompass the diameters of both the barrel and magazine tube.

• 5

  Secure the bar stock in a drill press. Select the appropriate drill bit -- one that corresponds to the barrel circumference plus 1/64 inches. Drill out the stencil all the way through the stock. Deburr the cut edges using a round metal file and abrasive paper until smooth.

• 6

  Shape the top and side exterior of the bar stock to mimic the outer contours of the barrel using a metal sanding drum and a file. Secure the shaped band upside-down in a bench vise. Cut through the center of the stock, using a rotary tool with a cutting bit, until you breech the drilled circle. The cut needs to be 1/32 inches wide, and cut in such a manner that it runs parallel with the barrel when the band is installed on the weapon. This will give enough space for clamp-tightening later.

• 7

  Taper the sides of the bottom end that you just cut to 45 degrees inward using a sanding drum or file. While the band is still in the vise upside down, drill two 1/16 inch diameter holes spaced evenly apart through the bottom flat part of the band. Here you'll be drilling through the cut that you just made. The holes will be used for screws that will tighten the band to the barrel.

• 8

  Tap the holes using a 6-40 tap tool. Work the tap in 1/4 turn, then back it out 1/4 turn. Keep repeating this process until the holes are tapped all the way through.

• 9

  Slide the band onto the barrel to check for a fit. The band should slide right onto the barrel, giving just a slight bit of resistance. Position the band at the desired location. Insert two fitting screws into the holes and screw them in. Attach locking nuts to the opposite side and tighten them down. You can also use metal bonding solution when attaching the band for a snug fit, if you prefer.

Rear Sight Base

• 10

  Unload your weapon completely. Visually inspect the weapon to ensure that no live ammunition is present.

• 11

  Secure the weapon in a padded gun vise. Ensure that the rear portion of the receiver is accessible to work.

• 12

  Mark the area where you want to place the sight base if you are working with a smooth, flat receiver. Generally, you want to tap one or two holes in the receiver to secure the sight base.

• 13

  Measure the sight mount groove that you'll be installing on the base. Transfer the measurements to a piece of flat bar stock. Scribe the measurements onto the stock.

• 14

  True the bar stock down in a mill to your corresponding dimensions. File the needed angles and grooves to the dimensions corresponding to your sight. Drill pilot holes through the sight base using a drill or drill press. Clean up burring and rough edges on the sight base with a rat-tail file and abrasive paper.

• 15

  Drill and tap the holes for the receiver using a drill press and a fitting tap tool. Tap tool size will vary according to your screws and the size of sight base. Screw the sight base into the receiver.