Wedge work

Proceeding carefully sounds good. Don't make big changes to the gun... just clean up any 'burr', mostly alter the wedge.
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If a Manhattan goes together the same way a Colt does, the cylinder pin should bottom out in its hole in the barrel lug with the barrel/cylinder gap and end shake minimized. The wedge holds it in position. Carefully fit the wedge to the barrel and cylinder pin slots. You could use machinist's blue, marker or soot to check the fit.
 
Actually double check the fit. Very few of the replicas actually have the base pin long enough to seat in the barrel like they should. I had to make up nose buttons and fit them on five Italian made Colt replicas. Most, if not all the replicas rely on fitting the wedge just right to set the cylinder gap instead of simply locking the barrel against the base pin like it should.

How this fits will alter how the wedge fits.
 
BCRider, yes I have stumbled across two other improvised methods of maintaining a specific clearance regarding the arbour. One suggested drilling and tapping a metric set screw to the very nose of the arbour. Another mentioned the epoxy of brass washers to accomplish the same.
Lucky for me the reproduction wedge seemingly required very little sanding to discover the sweet spot.
Once the new nipples and nipple wrench arrives I will experiment at the range.

This is an original Manhattan btw.

Thanks
 
Never throw out old wrenches!
This Manhattan cylinder has one port too small and wrench number ML063 will not fit because the access port a bit too small.
I called TOTW seeking out a nipple wrench that will work on this five shot pocket pistol.(1849 size)
They were totally out of stock because they were looking for a new build contract for this wrench. Hillfolk saved by bacon.
Turns out about three years ago I had one for another project but the nipples seized so hard I actually bent the jaws this softer steel wrench sourced from TOTW.
While looking for an Allen wrench for a set screw I found this partially bent wrench. For sure softer metal than my other wrenches. TOTW was right.
But about 30 seconds with a small file it fit and easily loosened the last factory nipple.
Now I just wait for new parts!

Never throw out seemingly useless tools.
 
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