Clint:
You don't need to remove the grips. I carry a vise(with well padded jaws) to the range for the purpose. A couple of pieces of plywood works well as protection from the metal vise jaws. The wood also padded with a bit of old towel or other soft fabric. The lower frame of the revolver(part between cylinder and trigger guard), can slip into one end of the vise jaws, leaving the grip out of the way. Don't lock it into the jaws too tightly, otherwise you may damage the frame. Only enough pressure is needed to secure the revolver into the vise, well enough to hold it in place so it won't move around, while filing. Filing is done with a medium/fine, single-cut file. Its also a good idea to put several layers of tape on top of the barrel, to prevent it becoming marred by a slip of the file.
To start: From a solid rest, shoot a group at the range selected for sight regulation. No need to shoot six shots....three usually suffices. Note its position. The first group will likely be several inches below point of aim. After ensuring the revolver is unloaded, fit it into the vise and begin the process.
While keeping the file as square and level as possible...take a little metal off the front sight. Do not take much off at a time. A few light strokes, no more. Then shoot another group. Maintain the same sight picture and aiming point. Note its position. File a bit more. You should start to see the groups walk their way up the target, with each repetition. Repeat...a few strokes at a time, until aiming point and group match. It is a slow and patient process. Don't rush. Sounds pretty tedious, but... the whole job usually doesn't take much more than half an hour.
I file toward the muzzle end (revolver pointed safely downrange and away from me)....keeping the cut fairly level. Generally, I like the sight's profile to slope slightly forward. But you may finish it how you like. When done, I break the sharp edges with a fine diamond file, or stone. Plus, gently round the front and rear profile of the sight. Touch up the bright spots with some cold blue. Then you're done. Sounds more complex than it really is. The key is patience and a light touch on the file.
Hope this helps.
Alex
