So, I bought a big boy pistol...

Ok, truth time. All I used for this project was a handful of tools that will get me branded as a bubba. Hacksaw, various hand files, 150 and 220 sandpaper, a Canadian Tire brand dremel tool (that's right I admit it) and a rotary rasp in a 1/2" Milwaukee drill.

After chopping the barrel, I squared the muzzle with a flat file, then recessed the crown with the drill and rasp. Dressed the outer diameter and muzzle with a couple of files from one of those $5 mini kits (Canadian Tire again). Then using a piece of sandpaper on my fingertip I smoothed out the muzzle (simply rotating back and forth) until I was satisfied. That's pretty much all there was to it.

The dremel was used to cut the barrel rib for the sight install, and for freeing the sight from the cut off section of barrel.
 
I saw pictures of your bench and figured you had a lathe and a miiling machine behind you!

What you do have is patience and ability to work with hand tools. My son is a machinist apprentice and when he went to school they started him out with files etc before he got to use lathes and milling machines.
 
Wow man nice work!! I thought you used a lathe to do that crown. Hmm give me ideas about a rifle I have here. The good thing is there is lots of barrel to practice on. Thanks for the inspiration.
 
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