Sounds like good ideas to me.
If you "fix" one spot, it will only fail in another, JMHO.

Exactly so. My first thought was to build up the takedown lever to just clear the barrel extension, and build up the barrel extension lug to just clear the takedown lever (in open position). Then I would have close to 100% engagement.

But that's way too much thinking. It doesn't need to be that much - The X-ray of the 'real' Lugers show only ~50% engagement. Likewise, it doesn't need to be stellite tipped either - That would just push the 'weakest link' further along the chain, so to speak.

So a bit of weld on the front of the lug is, IMO, sufficient. It's more of an esthetic issue that anything to do with longevity, or functionality, or durability.

I liken myself to a dog, finding itself in a strange yard... :D

"I liken myself to a dog, finding itself in a strange yard... "

I resemble that remark! ;)

Update !
 

The lug on the barrel extension has been extended by welding. David Parker offered to take on the job of welding up the lug, and he did a great job. :thumbup:

I had asked for an oversize buildup of weld, so I could mill it down. So, here is the results:

1 - First pic shows the weld buildup as received from David.
2 - Second pic shows the top and three sides of the lug squared off. I left the sides and top .010" oversize. I can take it down more later, if desired.
3 - First test fit: The lug is .055" too long. I ended up making six cuts off the front of the lug to get it to where I think it should be.
4 - Barrel extension is now level with the front of the frame. Everything clears; everything functions.
5 - Side view of completed lug modification.
6 - Pic of the takedown lever and barrel extension lug showing how little engagement there is between the two (which was my original request, to see how much should be engaged).

I had estimated it would take .040" to make it flush; it took .050". I'm a happy clam! :D

I love it when a plan comes together! Nice work, yourself, Rich.

I'm not too confident of this 'engagement'...

http://forum.lugerforum.com/attachme...1&d=1538680526

The takedown lever has a cut in it to clear the curved bottom of the barrel extension...But it comes nowhere near it... :(

I'm trying to measure the gap between the lever and the bottom of the lug...But I know from the pic that it ain't much... :eek:

The lug now sticks down .085". I stuck a piece of masking tape to the front of the lug and 'painted' the takedown lever rear face with a magic marker...Assembled it and rapped the lug against the takedown lever a few times...The first pic shows the amount of engagement...About halfway...

Second pic shows amount of clearance between the barrel extension lug and frame cut...Third pic shows amount of clearance between takedown lever and frame broached cut...

Building up the barrel extension lug and/or the takedown lever isn't all that practical...Not without milling/broaching the frame (to allow more engagement surface)... :(

I'm going to check my 1900AE tomorrow to see how much 'engagement' surface it has...

Bonnie Blue got me up early so I dug my 1900AE out to check lug engagement. First, I measured how 'proud' the barrel extension was to the frame. It was .0035". Not bad for a 116 year old shooter. :)

Next I did the masking tape/marker thing - that's the first two pics. About 86% lug engagement by my rough calculation. :p

Third pic is the takedown lever. Slightly different from the P08 lever in my S/42 - The 'block' that engages the barrel extension lug is not cut for clearance when locked. It's square. Much better engagement than the P08. And way better than the Aimco. :thumbup:

You sure it is not 0.035" and not .0035?

Nice work and super pictures.

Three and one-half thousandths... :)

NOT thirty-five thousandths...

Sorry,
I didn't understand "proud" , I was thinking the height of the lug.
:)
I see the clearance or gap is 0.0035, in the picture. My bad.

Sarcasm. My favorite communication medium. :D

No, you can't see the .0035" gap, because I didn't take a picture of it. That's the thickness of a sheet of notebook paper; you couldn't see it from a pic. :)

I showed the barrel extension sticking out of the frame, and the barrel extension alone. With the masking tape. It showed up better in the second pic. :thumbup:

I forget where/who I picked up the "proud" expression from. Someone here, but I don't recall what they were referring to. :confused:

Edit: Here's a quick pic of the 1900AE in battery...With the .0035" extension sitting 'proud'... :evilgrin:

I had a chance to get some range time today, and took the OFM stainless Luger along with a new-to-me 1911. The 1911 has a stainless frame and a Sarco Brazilian army parts kit. :)

With the OFM Luger I shot 115gr FMJ w/5.25gr W231 & 1.150 OAL. I only shot 25 rounds. I had to stroke the toggle 2-3 times for each first shot. Not sure why that is. Maybe that's why the barrel/barrel extension/lug was .040" too far forward??? :confused:

I'll try polishing the feed ramp in the frame and barrel. Maybe see if I can get an angle measurement on the barrel ramp.

I noticed a bit of burnishing on the frame rail where the toggle knobs strike. Nothing major.

No stovepipes. 4-5 failure to feeds. All ejected OK. Most went flying by my head, as they raced for the farthest and darkest corners of the range. (Same with the .45 cases). :grr:

Magazine was super hard to load 5-6 rounds in. I guess I'll have to break down and buy a loading tool. Or make one...Yeah!!! :D

It actually shot better than I was expecting. I shot off a rest at 50 feet. The 1911 shot better. :rolleyes: