Making a Rossi big loop into a small one

[gyppo]

Hello CGN gunsmiths and DIYers,

I want to modify the lever on a Rossi ranch hand to a standard loop. I love the ranch hand, but that huge loop is quite annoying to cycle.

I have some basic fabrication and reasonable welding skills, what I'm wondering is if I can splice in some mild steel to create a new loop or if it's better to bend the existing lever. I've made a replacement as practice, it turned out great so I'd love to just weld it in, I'm just not sure if re-blueing the lever will look ok with two types of steel.
I may end up cerakoting the gun as well so it may not matter, but I'd still like some opinions on using the original metal (will be very hard to straighten perfectly!) or splice in my piece.

here is what I fabricated:

Thanks!
G

 

[gunpro]

i would suggest reconfigure the existing one as the first plan, keeps the metal consistent and should only require one weld. The fall back is your fabricated piece. instead of blueing, make the new loop black or stainless with KG gunkote or similar like product for the distinct custom look.

 

[Boomer686]

Lots of Rossi lever owners on here. Have you considered putting it up for trade in the EE?

 

[Can-down]

Someone or two did exactly what you are describing a few years back here on CGN, the ranch loop is ridiculously big and their regular loop is well regular.... the perfect loop to me is in between the two which is what you can do by cutting and custom bending the big one down to perfection.

I think Henry does a pretty nice shape for their larger loops. I like to move my firing hand forwards sometimes and use the outside of the loop as a semi pistol grip position for my three non trigger fingers to wrap around.... helps relax the wrist angle a bit.

 

[gyppo]

Lots of Rossi lever owners on here. Have you considered putting it up for trade in the EE?

I asked the warranty center for Rossi years ago and they said the levers had to be fitted to individual rifles and couldn't be straight swapped...
And besides it's too late!

I have a lot of finishing work to do and a bit more welding. The lever was a PITA to bend evenly as it's thisckess varied, and I cracked it in a few spots so had to weld and grind. I'll post more updates as I get the finish nicer.

 

[gyppo]

i would suggest reconfigure the existing one as the first plan, keeps the metal consistent and should only require one weld. The fall back is your fabricated piece. instead of blueing, make the new loop black or stainless with KG gunkote or similar like product for the distinct custom look.

Thanks Gunpro, your suggestion made too much sense so I got started at once!

 

[Can-down]

Looks pretty good gyppo, did you heat it at all when you were bending it?

 

[gyppo]

I did heat it up, but maybe not enough, I cracked it in 3 places and it broke off in one spot so I had to re-weld. Pretty tricky to weld without blowing through on the thinner edges. The thin metal cools really fast too so it's hard to keep heat in there. I had to fill and grind lots of times before I got a reasonable curve on the bottom but I'm pretty happy with it.




It's not perfect but after shaping with a belt sander and files, I sanded with 220, then 800 and 1500 grit sandpaper. I did a quick and dirty cold bluing job, reassembled, and it works fantastic! A bit larger than the standard lever and not by any means perfect, but it'll do for a bush gun.

Weight has gone down a few grams too, it is exactly 4.6 lbs in ranch hand furniture.


The way it should have come from the factory, in my opinion!

 

[alpining]

Nice job on this - Tough project, you made it look good in the end.

 

[nowarningshot]

Great idea. You could probably make some jigs, tool up, find a easier to work steel. After many hours, you could lose money making them.

 

[gunpro]

Thanks Gunpro, your suggestion made too much sense so I got started at once!

Glad you gave it a go! i have gone the other way on a couple Winchester 94's and Marlins in the past, so why not reverse the process. in the end if the owner is happy then just give-er.

 

[smokinbarrel]

I've always liked the square levers...that would be a nice custom touch...one of a kind. I often wonder how many really like those big levers, they look impractical to me.

 

[G_Alan]

Good job , ended up looking really nice.

 

[alpining]

Great idea. You could probably make some jigs, tool up, find a easier to work steel. After many hours, you could lose money making them.

Shhhh! Don't spoil the surprise!

But yeah, as a one-off, looks like fun.

 

[357Maximum]

Good job, finished product looks great. When I had mine I bought a reproduction Win 92 buttstock and a orginal 1892 lever both just bolted on.

 

[kjohn]

Nice work! I don’t like the “big loop” levers, so you are now back in the fold.

 

[Mr.Rigpig]

That looks very good, That hideously large lever was my biggest complaint on my ranch hand.

 

[Falconflyer]

Looks great, I'm not a fan of the large loop lever's either.

 

[gaff]

very sweet.