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There several good ways to install tapered round barrel underlugs, but I would like to share how I do it. 
I see on the net some makers solder the underlug on the barrel before inlet in wood. I do not like that method (for me) and so why not do it another way? Here is what I do: First photo gotta make the underlug so after annealing the brass I crimp it in half and then insert the face that will receive the key into the vice as shown. Once the correct diameter is acheived depending on barrel placement, the underlug is cut and filed as shown in the following photos. The web between the RR channel and barrel channel is nice and thin, (photo 2) which requires making a underlug that works, but does not encroach into the RR channel. Once I have the underlug made to fit, I do the inlet, but slighly oversizing the cutting. When the barrel is removed for cleaning after use, four underlugs that are too tight will for sure cause grief.
Next step, I placed two small strips of paper towel under the underlug in the inlet and then add a small drop of super glue to the barrel side of the underlug. I then quickly set the barrel in the channel on top op the new underlug and clamp down. After about two minutes I remove the barrel, clamp down the temporary glued on underlug, flux and then solder. Clean up the solder and then it is a done deal. As you can see on the finished underlug there are holes drilled in the underlug. My confidence in achieving full solder coverage at the underlug/barrel joint is boosted by having more entrances to place solder.
Larry
I see on the net some makers solder the underlug on the barrel before inlet in wood. I do not like that method (for me) and so why not do it another way? Here is what I do: First photo gotta make the underlug so after annealing the brass I crimp it in half and then insert the face that will receive the key into the vice as shown. Once the correct diameter is acheived depending on barrel placement, the underlug is cut and filed as shown in the following photos. The web between the RR channel and barrel channel is nice and thin, (photo 2) which requires making a underlug that works, but does not encroach into the RR channel. Once I have the underlug made to fit, I do the inlet, but slighly oversizing the cutting. When the barrel is removed for cleaning after use, four underlugs that are too tight will for sure cause grief.Next step, I placed two small strips of paper towel under the underlug in the inlet and then add a small drop of super glue to the barrel side of the underlug. I then quickly set the barrel in the channel on top op the new underlug and clamp down. After about two minutes I remove the barrel, clamp down the temporary glued on underlug, flux and then solder. Clean up the solder and then it is a done deal. As you can see on the finished underlug there are holes drilled in the underlug. My confidence in achieving full solder coverage at the underlug/barrel joint is boosted by having more entrances to place solder.
Larry
