This will be a rehash of what has gone before, but I decided to experiment on a couple of ideas I had, and take pictures so I would have a record.
I had originally made two barrels for this Gonzo project; after doing ~85% of the longer barrel, I decided to go in a different direction. So, I shelved the second barrel and started a third.
(1) The donor barrel - a Remington 700 barrel in 30-06 caliber.
(2) Turning down the barrel for the FN/Mauser carbine rear sight.
(3) Turning down the 'flange' that bears against the barrel extension ['receiver'].
Continuing operations on the Remington 30 cal barrel.
(4) Turning down the breech stub.
(5) Threading the breech stub.
(6) Cutting the stub to required length; turning relief.
(7) Final fitting the barrel extension to the threaded stub.
Chambering for 7.65 Parabellum.
(8, 9, 10) Cutting the chamber, 1/32" at a time.
(11) Final fitting the 7.65 Parabellum chamber.
Fabrication of the front sight base.
(12) Rectangular piece of steel drilled & tapped 1/2" x 28tpi and mounted in rotary indexing head to mill outer diameter.
(13) Milling the sides of the sight base flat.
(14) Chamfering the front of the base and milling the rear ramp.
(15) Turning down and threading the muzzle for the front sight base.
Now I'll mill the dovetail for the front sight blade.
(16) Cutting the dovetail.
(17) Milling the front sight blade from a piece of 3/8" steel bar.
(18) Blade has been dovetailed and is ready to be pressed in place.
(19) Blade has been squared to size and is being finish milled.
Test fitting the various pieces for fit and visual effect.
(20) Front sight screwed in place.
(21) Rear sight is a slip fit; it will be secured with screws later.
(22) Full length profile view.
Next will be making a keyhole spanner for the front sight base and a set of vise inserts for this barrel.