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Lifer
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As I recall, I think Rich doesn't even mill the front sight base until after fitting the barrel and chambering installed in the receiver... Am I correct about your 'magic' ?
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Lifer
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That doesn't help you...You have a barrel with a front sight base. If you chase your thread, you'll be able to screw it into your barrel extension and find out where you are. The thread is 20tpi which is .050" between threads. With a 'crush factor' of ~.004", the most you could be off is ~.046". That is, if you screwed it in all the way until you couldn't tighten it any more [by hand], and the front sight was exactly 12:00 o'clock, then you'd need to take .046" off the flange. But it won't be that much, so you could thin the flange and cut back the OAL and get a proper fit. But you would almost certainly need to deepen the chamber, and re-cut the extractor notch and feed ramp. Adding a shim to a mis-matched barrel/extension combination opens up similar cans of worms. Will it need tweaking? Cut chamber, notch, ramp? Thin the shim? There is a thread here somewhere where that was done with a OEM Luger barrel, but I've lost it... I would chase your barrel thread and see whatcha got...
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