My STEN project...

Oh,

And progress for the day....I got the .125" magwell box welded up this afternoon, but had to fix up a friend's AR-15 muzzle for him on the lathe, so not much other progress.

Pics to follow soon...

50:30, $378

NS
 
More progress tonight.

With the magwell box welded, I decided to flatten out the sides and make things look a bit more....refined? (Is that a word that should really apply to a Sten???)

Anyhow, took about 10-15 minutes per side with a flat bastard cut 10" file to smooth things down. The rounded edges are still kinda....ugly...but that's character!

The rear face which has to be a bunch closer to .100 than .125 took about 25 minutes to sort out so that the rear mag guide piece thingie fit properly.

Now I'm starting work on the collar.

I indexed my 1/4" hole, on my dewat it's .135" back from the front edge, so centered on .260" in. Center-drilled and then full size drilled.

Next is setting up the mag hole and ejection port hole. The magazine hole starts at .604" in from the front edge (or at least, that's the distance measured to the front of a magazine from the front of the collar.)

So, now I'm going to work on the magazine hole, get it all done up, then I can step over to the other side and do up the ejection port hole.

Progress is a good thing!

If this keeps up, I might have to book an appointment with the CFO next week sometime!

$378, 52:45

NS
 
Well, here are the progress pictures.

Firstoff, I'll start with the initial failed attempts...the first go with the 1/8" plate and the Lee Valley benders:

may%2008%20027%20(Small).jpg


This didn't work out so well. Not enough oomph to bend the plates!

Step over to the .075" flat steel.... this worked much more easily, but was way too thin for durability.

may%2008%20032%20(Small).jpg


Then, the mandrel arrived. So, here we are with the "spencer" method, note, I did not end up grinding/filing the edges down to fit properly, I was only after the shape/form.

may%2008%20035%20(Small).jpg


Now, here we are after 15-20 minutes of pounding away with a hammer on the mandrel. I'm 3/4 of the way around the mandrel now with the piece of steel, and it's working quite well.

may%2008%20039%20(Small).jpg


(As you can see, I ended up finding a good use for those Lee Valley Metal benders!!!!)

Here's the finished product, wrapped around the mandrel:

may%2008%20040%20(Small).jpg


Here we are with a magazine stuck into it after it was welded. A nice tight fit!

may%2008%20044%20(Small).jpg


Next Step....but here's a bit of a preview of where I'm headed:

may%2008%20045%20(Small).jpg


A progression of pictures showing how a hammered up, vise marked side can be turned into a smooth, flat with about 10 - 15 minutes of file work:

may%2008%20051%20(Small).jpg


Step 2:

may%2008%20052%20(Small).jpg


Done!

may%2008%20053%20(Small).jpg


This is the rear of the mag well. I spent a bit longer with it than the other three sides, since I had to reduce the thickness to a specific amount (.100) to allow the mag spacer plate to fit properly:

may%2008%20054%20(Small).jpg


Started:

may%2008%20055%20(Small).jpg


Done, with the mag fitting, and the mag spacer!

may%2008%20057%20(Small).jpg


Then I realized my day would not be complete without working a bit more on this, so here's the next shot:

The .25" indexing hole located an drilled:

may%2008%20058%20(Small).jpg


The first line of holes drilled:

may%2008%20059%20(Small).jpg


The mag entry side, drilled out, ready for some work with the file:

may%2008%20060%20(Small).jpg


And so, the fruits of my labours throughout the day yesterday and today:

may%2008%20061%20(Small).jpg


I need to file in the recess area for the magwell to fit to the collar, but overall, a VERY pleasing day! I can see me getting the bits for this finished up tomorrow and ready to weld! have to go pay another visit to the uncle!

NS
 
Well,

Things have progressed very well this weekend, so well in fact that I find myself needing a Bolt in order to be able to go any further.

Alas, with the group buy not working out, there's no bolts to be had.

The unfinished one I commenced work on looks like the most promising thing on my horizon right now, and since my Sherline hasn't sold yet, I brought it back into the shop to get working again. *sigh* It's sooooo bloody slow!

Anyhow, 3 hours later, and I've got the flat cut on the side of the bolt for the feed lips, I've got the ejector slot milled in, and the feed lip area relieved up to the bolt face.

Pics to follow before long, but I'm thinking that it might actually be possible for me to get this bolt done.

Tolerances are a bit....well....maybe not as tight as the factory bolt, but hey, it should still work, (I hope!)

Anyhow, that's where I'm at.

NS
 
So, total time on the project today, almost 10 hours.

Damn that Sherline is SLOW.

I'm pretty sure that with a real sized machine, you could accomplish what I did today in, um, around 20 minutes or so of actual cutting time.

*sigh*

Anyhow. I now have feed lips, relieved for the magazine on the left side, I have the two notches on the bottom of the bolt, and I have an extractor slot cut and spring hole drilled. Of note, I rather luckily found a .200" end mill in a pile I got a while ago....made cutting that .200" slot MUCH easier than making multiple passes with a .125 end mill (the other option.)

So, here's my task list:

1. Build locator pin thingie for front of magwell

2. Drill extractor pin hole

3. Install extractor

4. Weld trunnion/trigger mech to tube

5. Weld ejector into tube

6. Weld mag box to collar

7. Stamp Serial Number on mag Box

8. Register Receiver with CFO

I can see this happening this week!

I have a pile of parts that are really starting to look like a Sten!

Life is good!

As an aside, Stencollector, in your thread, you mentioned that the SAS guy sent you a few parts including the new style hammer....is he still able to ship those bits up to Canada? Looking at the mill work on the Hammer, I'm pretty sure I'm looking at almost 10 MORE hours of milling to finish that piece up!

So, here's the running totals:

$378

64:15

Note, at least 18 hours of this production time has been me building this bloody bolt on the Sherline. If you had a real milling machine, I'm pretty sure you could build it in about 4 hours.

NS

(Pics to follow tomorrow, I'm too tired just now.)
 
Ok,

Here's the promised pics from the bolt work...

Here's where I started....

may%2008%20062%20(Small).jpg


About 1/2 done with the fly cutter:

may%2008%20063%20(Small).jpg


Here's the bottom done, with the slot for the ejector milled in. As you can see, I have already removed the ends where the feed lips will go.

may%2008%20066%20(Small).jpg


Getting started on the relief cuts for the magazine lips:

may%2008%20070%20(Small).jpg


One side down, starting on #2:

may%2008%20071%20(Small).jpg


Note at the rear of the ejector slot, I milled in an extra recess to allow the original ejector to be used without having to modify the rear of it.

Here we are, feed lip side complete:

may%2008%20073%20(Small).jpg


Here's the start of the extractor slot: I drilled the hole first (9/32 I think it was) for the spring, then switched to a .200" end mill.

may%2008%20076%20(Small).jpg


Here's the extractor cutout completed:

may%2008%20077%20(Small).jpg


And, you can see here the final product of last night's work:

may%2008%20078%20(Small).jpg


Things are going alright!

NS
 
Well damn.

Remember the rule...Measure twice, cut once?

Yeah.

Oops.

So, my extractor retaining pin hole is .330 in from the side of the bolt, not .380, meaning that my extractor sits somewhat proud from the side of the bolt....DOH.

So, I'm busy building a new extractor right now. *shrug* That's life.

I didn't see a good way to move the hold in the extractor .050 out. Whaddya do, eh?

NS
 
NavyShooter said:
As an aside, Stencollector, in your thread, you mentioned that the SAS guy sent you a few parts including the new style hammer....is he still able to ship those bits up to Canada? Looking at the mill work on the Hammer, I'm pretty sure I'm looking at almost 10 MORE hours of milling to finish that piece up!
Click to expand...

The new style hammer is a fairly simple part in my books. Not sure it would do you much good without modification, since your guide rods are spaced differently.

Rather than milling the hammer out from scratch, you could make it from inch or so of roundstock the appropriate length, and cut a groove into it. Make the striker portion from a seperate piece of steel and weld them together.

At that time he had no problem shipping out the hammer, springs, guide rods. The bolt itself would be a controlled item on the US side for export.
 
Ok,

New extractor constructed and fitted.

It works.

Revised list of stuff to do.

Bolt:

1. Firing pin hole (finish drilling) -waiting on proper sized drill bit.

2. Firing pin retaining pin hole (Measure 3 times, cut once.)

3. Cocking handle hole

4. Cocking handle

That will complete my bolt. I'll still have the hammer, springs, guide rods, etc to worry about, but that's a work in progress.

Gun tube:

1. Weld trunnion/trigger/ejector into place and dress welds.

2. Stamp serial no on trigger

That will complete my "tube".

Magazine well/collar:

1. Build lock piece ring on front of magwell.

2. Weld collar/magwell/lock piece into place.

3. Stamp serial numbers

4. Register

5. Complete fitting of magazine latch/etc.

That's what I see as really left on my project!

Things are going VERY WELL!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

NS
 
I'll probably harden it, we'll see if cycling it ends up dinging it up much, and I'll see what to do from there.

Progress for tonight involved getting the cocking handle built. I drilled out a 0.500" hole, then bottomed it out with a 1/2" end mill. I think there's some runout though, since the 1/2" rod I used was slightly loose, so there's some rocking in the handle, so I'll get some larger stock and turn it down later. Minor.

Manually cycling the bolt felt pretty damn good. I put an old Sten spring in the rear of the action and cycled it against that in the tube...DAMN what a feeling, things are coming together!

:)

I'm at the point now where (with manually cycling the bolt) that I can actually get the mag box welded together and test-cycle rounds. Life is good!

NS

NS
 
The SAS design uses an AR firing pin, no doubt because BATFE mandate a floating firing pin, the AR is readily available, and, it works. It is also a design that makes drilling the firing pin hole more complicated than necessary. I suspect it would be easier to go with a shop made drill rod pin that would require a simpler installation.
 
Application process commenced, the CFC tech will likely be in the area in the near future, thus allowing him to see it first-hand without having to ship it out of the area.

NS
 
Photos of the project (magwell/collar, receiver tube, and bolt) have now been sent to the appropriate CFC person, with copies to my CFO.

I don't think their inboxes like me now ;-)

At least I was nice and re-sized the pictures!

NS
 
Danke Shortandlong!

I'm able to report some progress on the project.

My Bolt is 95% complete (need to finish the firing pin hole)

My hammer is complete

My recoil spring guides are complete, and awaiting correct springs

My tube has been welded together and partially dressed up.

My Receiver/Magwell/collar has been welded, and is in process of being registered. I expect to meet with the CFO and a CFC Tech on tuesday or wednesday.

I have test-cycled the bolt and hammer with improvised springs, and it cycles correctly as a semi-auto, with the hammer resetting the sear every shot.

Things I'm waiting on:

1. Firing pin hole drill bit

2. Firing pin retaining pin hole

3. Complete registration process and finish the receiver (magwell/collar)

4. Build barrel (either use shortened recovered length from original DEWAT kit, or new barrel when it arrives)

5. Final fitting/adjustment

6. Test-fire

I'm getting close gang! It's a damn fine feeling to be able to rack the cocking handle, pull the trigger, have the hammer fall, hold the trigger back, cycle the bolt, release the trigger, have it reset, then drop the hammer again!

DAMN!!!!! I might get to shoot it before I go to Bisley!!!!!

So, here's the new totals:

$378

84:15

NavyShooter

(Pics to follow mid-week.)
 
Last edited:
*Shrug*

That's a minor issue if you ask me.

If I mess up drilling the hole, then I'll just custom-turn a dedicated firing pin. I've made pretty much everything else, what's one more piece?

Oh, and as an aside, I found springs that seem to work...an old FN-C1 recoil spring, inner. Cut to the correct lengths, seems to work OK, though a bit stiff. We'll see if it works. Call it a maybe.

NS
 
Built a new cocking handle this afternoon.

The old was was a bit rattly/loose. It was from .500" stock, going into a .500" hole that had a bit of runout, so was actually around .509. So, I took some 3/4" stock, turned it down to .508, and fitted it in.

A nice, tight, smooth fit now :)

(P.S. I have a copy of the CAFC 804 form in the case with it right now!)

NS
 
You must log in or register to reply here.
Back
Top Bottom