John and Dwight,
A few measurements on my 7.65 1906 shows the barrel wall thickness to be .072" at thinest point just behind the front sight base.
IMO This is too thin for relining using the same metal as the original barrel metal.
I am of the opinion that the safest route would be to find a modern high strength steel of the same strength as SAE 6150 steel (Chrome molybdenium steel of the type used in automotive Leaf and Coil Springs).
Many modern custom WildCat Barrels are made from this steel because of the very high breech pressures encountered.
A little shopping around could possibly turn up a barrel made for the old 7.65 06 or larger volume case.
I would make the liner at least 75% of the thickness or .050 to .055 inch hickness.
leaving .017 to 020 inch wall of the original barrel.
I believe that this would be a safe combination if the liner were a .003" interference shrink fit with the old barrel.
This hould be accomplished by freezing the liner in Dry Ice and Acetone, and Heating the Barrel to a very dark straw temprature.
The liner must be inserted in alignment within 0.1 to 0.2 seconds, or the liner must be drilled and reamed out of the barrel and you start over.
Viggo
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