Another .36 cal Rifle from a Plank

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Made a decision to duplicate a patchbox I did on another rifle in 2012 and gave away. I don't have one like it and I like the asymmetric design. Here is the layout.....





The door in 0.050" material. The side pieces are cut out of .032" brass.....





Then I contoured the door to the curvature of the stock and prepared one side of the hinge I made earlier for silver soldering to the door.....













I ran out of the appropriate thickness of brass sheet to make the top of the box. Material is on order. Once that is cut out and contoured, I will attach the opposite side of the hinge in the same way.
 
was gone for a month and more. Today I had a chance to print out a copy of a patchbox I did on another rifle (in 2012 or 2014), scaled it to size, printed it, and glued the print on the sheet brass. Got it cut out with a jeweler's saw and mostly cleaned up with needle files. Needs a little more work before I contour it to the stock and start the inletting.






 
Finished the assembly of the door / hinge / finial of the patch box. Finished shaping the finial after cutting it out. Then burnt off the pattern and annealed the brass. By hand bending and the use of a small rubber hammer, I contoured the finial roughly to the stock shape. Filed the second half of the hinge to fit the curve of the finial plate and then hard soldered the hinge half in place. With all the parts made, I can start the inletting of the box......always fun !










 
I always engrave the box off the gun.....along with anything else I can. The thin brass parts will need to be well supported to keep from deforming them so I usually attach them to wood blocks with "cold cure" dental acrylic or just super glue them to well fitted hardwood blocks. Either will release quickly with a little heat. These photos are of a patch box for a scaled down longrifle I did for my 5 year old grandson......( https://www.muzzleloadingforum.com/threads/a-tale-of-two-little-rifles.145222/ )



 
Patch box parts fitted and then removed from the stock for mounting and engraving.....



Also installed the patch box closure spring in the stock and mounted the closure stud on the door lid. Cut a square hole in the lid, filed a square shank end on the stud, and then peened the stud into the hole. Also silver soldered the stud on the underside of the door.....







Back to engraving.....did the layout dye thing and then sketched the general outlines (very lightly) with a scribe point.....Started in on the side plates. Not done with all the details yet but have the general outlines and some shading done. Will get the finial and door to the same place and then go back for the finishing touches.





 
Cut a square hole in the
Can you please go over how? I have an unmentionable project I need to do similar on....
then peened the stud into the hole
Does this negate any need for the square hole to be a perfect size? Essentially fitting the stud to the hole instead of creating a square hole for a specific size stud?
I need a square hole to fit over an existing part, ideally not all the way through, but I can work around this if I have to.
 
Can you please go over how? I have an unmentionable project I need to do similar on....

Does this negate any need for the square hole to be a perfect size? Essentially fitting the stud to the hole instead of creating a square hole for a specific size stud?
I need a square hole to fit over an existing part, ideally not all the way through, but I can work around this if I have to.
Brokennock,

I neglected to take pictures but my usual method is to first file the square shaft end to size. Then I drill a hole in what will be the female side just a bit smaller than the minimum dimension on the square shaft. Then as closely as possible, I file the round hole square with a needle file test fitting all along the process. When the hole size is very close I usually tap the square shaft into place insuring a really good fit. Then after removing the square shaft, I use the same needle file to slightly bevel the outboard edges of the square hole. The shaft is then replaced in the hole, held tightly in a vise, and the protruding end of the square shaft is then peened into place and finished off flush with a file. The tighter the fit the better this all works, so a loose fitting square / hole will usually be unsatisfactory. Peening will not really make up for a poor fit....it can be made to work but will probably wiggle.

It sounds like you need (or would prefer) a blind square hole. Much harder to do. Depending on the size, there are various methods of producing the correct size blind square hole. The easiest and best would probably involve either EDMing the hole entirely or blind drilling a slightly undersized round hole and then making and using a hardened square punch to make the round hole square. (This last method is often used to produce the female hexagonal drive hole in the head of hex bolts.)

Hope this helps.
 
In Japan, they sometimes recognize and bestow upon an exceptionally gifted person, the status of a “National Treasure”.
I would never surprise me in the least- if we had this tradition in the US- if such a regognition was given you.
Pathfinder,

Thank you for the very kind (but undeserved) compliment. I'm learning (slowly) but there are many, many builders / engravers working out there that are much more worthy of the "National Treasure" status. I just like to try as best I can to emulate their work. :)
 
Unbelievable! What a beautiful job! Is this the first time you’re doing this? Lol
I’m kidding. Simply amazing. Great great job.
 
Brokennock,

I neglected to take pictures but my usual method is to first file the square shaft end to size. Then I drill a hole in what will be the female side just a bit smaller than the minimum dimension on the square shaft. Then as closely as possible, I file the round hole square with a needle file test fitting all along the process. When the hole size is very close I usually tap the square shaft into place insuring a really good fit. Then after removing the square shaft, I use the same needle file to slightly bevel the outboard edges of the square hole. The shaft is then replaced in the hole, held tightly in a vise, and the protruding end of the square shaft is then peened into place and finished off flush with a file. The tighter the fit the better this all works, so a loose fitting square / hole will usually be unsatisfactory. Peening will not really make up for a poor fit....it can be made to work but will probably wiggle.

It sounds like you need (or would prefer) a blind square hole. Much harder to do. Depending on the size, there are various methods of producing the correct size blind square hole. The easiest and best would probably involve either EDMing the hole entirely or blind drilling a slightly undersized round hole and then making and using a hardened square punch to make the round hole square. (This last method is often used to produce the female hexagonal drive hole in the head of hex bolts.)

Hope this helps.
Thank you very much.
This is roughly what I expected, the drilling then filing the round hole square. Good to know the sizing process. I'll probably need to practice on some scrap material.
A blind square hole would be perfect, but I don't have the capability and the project isn't worth enough to spend the money to have someone wire EDM it, but I admit I hadn't thought of that.
Thank you again.
 
Got the bulk of the patch box engraving completed today including sweating on the sterling silver onlay. Still some details to attend to and the photo below of the whole box is just loosely placed on the stock. The final fitting still needs to be done. Need to plan out the rest of the engraving on the trigger guard, toe plate, ramrod pipes, etc., and get those done.






 
Back from traveling for a while and had some time to work on getting ready to stain and finish this rifle. There was a recent thread on applying iron nitrate solution more than once, how long to let an application dry before heat blushing, etc, etc. And of course, anyone who has ever used a stain on wood knows that the wood gets a vote as well. Different pieces of even the same species of wood will take stain differently. In addition, different ways of preparing iron nitrate solutions will give different results. The following is not an exhaustive study by any means, but it sufficient for me to decide how I want to stain this particular rifle. I post it here as it may be useful to others.

To start, the strip of wood I am using came off thew left side of the stock along the barrel. The surface was sanded to 320 and then four different solutions of iron nitrate were used to stain short sections of the wood. The fifth solution was 70% nitric acid only cut 50 / 50 with water just to see what effect nitric acid alone would have on coloring the wood. The following picture shows all five solutions and the result of a single application of each solution which was then allowed to dry. Subsequent heat blushing left each solution as you see it. No finish was applied but the surface was wetted with mineral spirits before the picture was taken. PS....click on the pictures and make them larger.....easier to see the resulting stain color.



Let me describe how each iron nitrate solution was prepared. Starting from the left:

1) The first solution is the plain 35% nitric acid alone containing no iron at all. As a note, I should have also tried the full strength 70% acid as well....but I didn't.

2) The second bottle contains an iron nitrate solution I prepared in 2009 in accordance with information Bill Knight had published. In short, it involved dissolving nails in concentrated nitric acid in an ice bath (to keep the solution temperature from getting too high) and adding nails until the acid was exhausted. The bottle was kept loosely caped for several weeks as the reaction continues for some time and can build pressure in the bottle.

3) The third bottle contains an iron nitrate solution made by adding 14 grams of ferric nitrate crystals to 150 milliliters of denatured ethanol. The ferric nitrate goes immediately into solution but after a few days an orange precipitate forms. When applying the solution, I shook the bottle and applied the precipitate with the solution.

4) The fourth solution was prepared, again with ferric nitrate crystals, this time added to distilled water until the solution was saturated (i.e.no more ferric nitrate would disolve at room temperature).

5) The last bottle contains a much weaker solution of ferric nitrate made with 1 teaspoon of ferric nitrate in 200 milliliters of water.

The top photo here shows the wood strip and all the bottles of various solutions. The next two pictures show closer pictures so that you can see the effect of each stain a little better. All thee photos were taken in afternoon sunlight.





Personally, the two most concentrated solution produced a color I liked the best (#2 and #4). Not surprising that they would produce the darkest color in one pass. However, the Bill Knight version (#3) came out a little more brown while #2 and #4 were a little more red. The weak solution (#5) is very brown and did not produce a very pleasing color or accentuation of the grain (in my opinion).

Just thought others might like to see the results of this quick test. One final note, actual finish would make the stain results show even better. Wetting with mineral spirits was just a quick expedient.
 
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