40 Caliber Volcanic Rifle,

Charlie · Post by **Charlie** » Sun Jan 17, 2010 12:03 pm

And the Wood is fitted to the Metal, and the Metal is fitted to the Wood.

Now, we need to make em round and purty.

Alan Wood · Post by **Alan Wood** » Sun Jan 17, 2010 5:59 pm

Man you are making quick progress on thie project! And it looks very good indeed!

Bis · Post by **Bis** » Sun Jan 17, 2010 6:57 pm

Its already purty

Charlie · Post by **Charlie** » Tue Jan 19, 2010 7:00 pm

The Receiver is finished with the exception of a Dove Tail for the rear sight.

Charlie · Post by **Charlie** » Tue Jan 19, 2010 7:07 pm

Here is that square and blocky Lever after 5.5 hours of filing and polishing.

Ben_Rumson · Post by **Ben_Rumson** » Tue Jan 19, 2010 11:21 pm

Sweet!

Halfbreed · Post by **Halfbreed** » Wed Jan 20, 2010 4:19 am

I am just blown away at this project... WOW! Any engraving planned for the receiver?

Charlie · Post by **Charlie** » Wed Jan 20, 2010 7:54 am

Thank you Ben.

Halfbreed, I am not really a fan of engraving, but for this baby, I will commission "Rick Simmons" To do something akin to the original factory stuff these guns had.

Ricks has incredable skills, equal to anyone alive today, and he is afforadable

Here is the Hammer and Lever Screws. These were made from O-1 Tool Steel and quenched in Oil. I then polished them and Fire Blued em. I let the Fire Blue process remove the brittleness, sort of like killing two Rocks with one Bird.

These are Custom #10-32's.

Charlie · Post by **Charlie** » Wed Jan 20, 2010 6:25 pm

I made it round and purty.

Charlie · Post by **Charlie** » Wed Jan 20, 2010 6:29 pm

Remember I said the "Henry" was an enlarged "Volcanic"?

See what I mean.

Bis · Post by **Bis** » Wed Jan 20, 2010 6:55 pm

WOW. That is impressive.

Post by **AmBraCol** » Wed Jan 20, 2010 9:37 pm

Thanks for sharing this build with us. It is indeed a lovely rifle. Is the barrel/magtube going to be blued? If I'm looking carefully, you've still not fitted the rear sight. I look forward to seeing what you do there. This has been fun.

Alan Wood · Post by **Alan Wood** » Wed Jan 20, 2010 10:31 pm

Round and Pretty indeed. Very well done Charlie! Thank you for sharing.

kimwcook · Post by **kimwcook** » Thu Jan 21, 2010 5:10 pm

Charlie, that's just off the chart impressive.

JerryB · Post by **JerryB** » Sat Jan 23, 2010 10:13 pm

Beautiful rifle, thanks for letting me watch.

soon 2 retire · Post by **soon 2 retire** » Sun Jan 24, 2010 8:12 pm

Charlie, I'm impressed with the hand work that goes into the final fit and shaping. Sort of like in wooden boat building where material is removed to "make it fair". I was looking at the Italian shotgun manufacturer - Fausti Stephano's website and there was a picture entitled "gunmaker's tools". The only tools shown in the photo were files. Not many stop to think about the importance of hand tools in the manufacture of firearms. Keep it coming.

Bob in NE Indiana

Charlie · Post by **Charlie** » Tue Jan 26, 2010 10:24 pm

It's a Sight.

Sight Installed.

Alan Wood · Post by **Alan Wood** » Tue Jan 26, 2010 10:32 pm

Now that's a site to behold. Is that sight the original style? At the time I would have thought that an adjusting screw like that would have been a rather expensive bit of hand fitting.

Post by **AmBraCol** » Tue Jan 26, 2010 10:53 pm

NOW I understand why the dovetail was so far forward on the receiver.

Looks sweet.

Charlie · Post by **Charlie** » Wed Jan 27, 2010 8:20 am

Alan Wood wrote:Now that's a site to behold. Is that sight the original style? At the time I would have thought that an adjusting screw like that would have been a rather expensive bit of hand fitting.

Yeah, that is the way they did it. After doing it, it was learned that this kind of sight (notch) did not work very well this close to the eye. It was then moved to the Barrel.

A peep sight would have been just the ticket here.

Thank you AmBraCol.

nemhed · Post by **nemhed** » Wed Jan 27, 2010 12:57 pm

That's just an unbelievable display of skill! Any estimates on how much time and money you have wrapped up in that project?

Bis · Post by **Bis** » Wed Jan 27, 2010 6:02 pm

I was going to ask the same question, how much time do you have invested. For me it would be measured in years .

Charlie · Post by **Charlie** » Thu Jan 28, 2010 9:47 am

You are right Biz. I started trying to figure out how to do a modern Volcanic seven or eight years ago. I have gone through 5 or 6 different designs for the mechanism, spent nearly a year learning and making a 40 caliber barrel, I mean doing the rifleing and all. I still can not do a long barrel (over 8") so I had to use a blank here. Sence I am not doing this for profit, I don't worry about time at all. Those 2 screws ( Hammer and Lever) cost me about 4 hours, design machining, and heat treating. And that's just 2 silly little screws that you think I would purchasse at a hardware store for less than 2 bucks! So here I have 4 hours invested in 2 screws, at 65 or 75 dollars an hour (standard machine shop time) dem babys are expensive! Take a drawing of these 2 screws to a Job Shop, you already have the design, all the man has to do is purchase the material and machine them out, then heat treat em. Tell him you don't want any favors, tell him to charge his standard rate, see what he says!

You godda love it Man, if you don't, you will never invest this time and effort.

How much time? It's a life style man.

Now I am a pretty good machinist, and I can compete with professional machinist in the time it takes to make a part, but then I am the one who designed that part. How long was I thinking about what that part would look like, and how would I make it?

It would take appreciable time to go back and estimate the time, and materials and design for each part. I would much rather take this time required to estimate, and make some more parts.

So what would I charge to make this gun for some one else?

At this time, I would not take such a comission.

Ben_Rumson · Post by **Ben_Rumson** » Thu Jan 28, 2010 10:13 am

The whole thing is simply marvelous Charlie..Really a vision..

How were the tangs were done?..

Charlie · Post by **Charlie** » Thu Jan 28, 2010 10:42 am

Ben_Rumson wrote:The whole thing is simply marvelous Charlie..Really a vision..

How were the tangs were done?..

Let me get a picture, I have done this 2 different ways.

All will be explained.

gimdandy · Post by **gimdandy** » Mon Feb 01, 2010 10:34 am

Charlie,
When I am able to have computer time I come here first. Since I just now found this article I was lucky enough to be able to read it clear through.WHAT A TREAT THIS HAS BEEN............THANK YOU SIR !

olyinaz · Post by **olyinaz** » Fri Feb 05, 2010 12:33 pm

Looking good Charlie!

You may have answered this already but I missed it if so: I was wondering, while looking at that lovely receiver in the white, how you're going to finish it? Any chance you'll have it color case hardened? What did you have in mind?

Thanks,
Oly

Winnetou · Post by **Winnetou** » Sat Feb 06, 2010 12:37 am

The receiver is aluminium. But that brings up other possibilities, such as colour anodising, which also makes the surface harder. If this receiver were anodised dark blue, I suspect it would look like nitre/fire blue on steel. On the other hand, if anodised in brass colour, it would look like an original Volcanic.

I must say that this was an extraordinarily impressive thread and project. What a beautiful rifle!

If this version were on the market, I would purchase one immediately.

Charlie · Post by **Charlie** » Sat Feb 06, 2010 9:11 am

Thank you Winnetou.

I plan to leave the Receiver it's natural color to mimic the Silver Plated Brass ones that were offered for an additional $5.00 !

I would have Hard anodized it except the side plates would no longer fit. The anodizing adds dimension to the parts, and they were very close to began with.
I could have made them smaller, and the Anodizing bring them to size, but that is a guessing game.

I'm with you man, that Volcanic is a beautiful rifle.

I know it's a lot of trouble making custom Cartridges for this baby but I'm delighted with the way it shoots. That big 40 caliber Bullet comes out of that barrel at a little over 900 FPS giveng me about 280 foots pounds of energy. The recoil is very mild, and so is the noise. I don't feel the need for hear protection. I have shot it several times inside my closed garage!

I have the gun dissasembled at this time, Rust Blueing the Barrel and other hardware. I will post pictures of the finished rifle in about a week. Then I,m gonna taker to a 50 yard range and sight her in.

Allagorically speaking, she was a teen age Lever Gun, nothing else ever equaled her in fresh preportions, grace, and class.

44magHunter · Post by **44magHunter** » Sat Feb 06, 2010 11:59 pm

Your rifle project is truely amazing. Thank you so much for sharing this with us. You are truely gifted.

gregg · Post by **gregg** » Sun Feb 07, 2010 11:11 am

44magHunter wrote:Your rifle project is truely amazing. Thank you so much for sharing this with us. You are truely gifted.

Wow oh wow.. What does it weight?
What a woods gun.
Did I say wow yet well wow

Charlie · Post by **Charlie** » Sun Feb 07, 2010 1:49 pm

Thank You MagHunter.

gregg, she weighs about 5 pounds and 4 ounces, but she will hold 21 Cartridges, and that will add appreciable to the carying weight.

Charlie · Post by **Charlie** » Sun Feb 07, 2010 1:56 pm

She's finished.

Hey Guys, I hope you have enjoyed seeing how Charlie does it.
I hope you have developed a higher regard for the very first Lever Gun, the "Volcanic" (as we visulize a lever gun to be)
I hope some of you have been inspired to build your own Lever Gun.
For those of you that have taken the time to extend a compliment to me, receive my sincerest thank you.
You are appreciated more than you relize. Your encouragement motivated me to continue posting here, and there may be others that got someting out of this and choose not to say anything.

I also want to extend a big "THANK YOU" to Hobie for making this a sticky.

Any questions, I would be pleased to answer, (if I know)

We may do it again some day,
have fun my Friends.

Charlie

Ben_Rumson · Post by **Ben_Rumson** » Sun Feb 07, 2010 3:39 pm

Let me be the first to say Congrats !! Looks great... thanks again.

gregg · Post by **gregg** » Sun Feb 07, 2010 7:36 pm

Ben_Rumson wrote:Let me be the first to say Congrats !! Looks great... thanks again.

Ben
Ya right let me be first!!!IF i HAD NOT SPIT WATER IN MY KEY BOARD THAT I had to dry out you would not been first!!!

That there a lie

But she is a looker .

Post by **AmBraCol** » Sun Feb 07, 2010 8:49 pm

Sweet! Thanks for sharing the process with us, from blueprint to bluing.

Now, what's next? Doc Hudson votes for a matched pair of Merwin & Hulbert resolvers. You mentioned something about a '92 Winchester. Inquiring minds want to know.

Alan Wood · Post by **Alan Wood** » Sun Feb 07, 2010 9:34 pm

Looks even better now that it's done. Cogratulations! And thank you for sharing.

Bis · Post by **Bis** » Sun Feb 07, 2010 10:22 pm

Looks great, a beatiful weapon. Now go out and enjoy the fruits of your labor and let us know how it shoots.

Old Skirmisher · Post by **Old Skirmisher** » Mon Feb 08, 2010 7:56 am

Charlie, It's amazing what a good man can do with his own hands. The beauty of your rifle helps me to appreciate the looks of my Uberti Henry.

RIHMFIRE · Post by **RIHMFIRE** » Fri Feb 12, 2010 7:54 am

awesome!

Ron Macy · Post by **Ron Macy** » Fri Feb 12, 2010 7:58 am

I was looking at a posting on Family Friends Firearms site about a 1891 S&W .22 cal target pistol and thinking how great it would be to have the skills needed to build one of those.

Then I ran across these levergun postings and I’m stunned at the abilities of you machinists to work in a no mistakes allowed environment.

You gentlemen deserve all the accolades and respect offered for your work.

Congratulations.

kimwcook · Post by **kimwcook** » Sat Feb 13, 2010 9:58 am

That was a fantastic trip, Charlie. Beautiful piece that you can honestly be proud of. Thank you.

Griff · Post by **Griff** » Sat Feb 13, 2010 10:15 am

Again, WOW! To you it may seem like a project... time and materials... but to me... it's like magic.

Post by **Hobie** » Sun Feb 14, 2010 10:04 pm

As agreed to by Charlie I have consolidated his posts into one article on my blog. It does take some time to load and I do have a bit of tweaking to do.

Alphawolf45 · Post by **Alphawolf45** » Tue Feb 16, 2010 10:54 am

Wow Charlie I like how you made that buttplate..Matching the profile of top of the receiver, very sharp.....Gonna make a video now?..

olyinaz · Post by **olyinaz** » Tue Feb 23, 2010 1:47 am

Looks great!

I'd really like to see it shooting in action so I'll second the request for a video.

Thanks for posting!

Best,
Oly

Charlie · Post by **Charlie** » Tue Feb 23, 2010 8:17 am

Yes, I'm gonna make a video. I will post it when I get em.

I love the way this Lady shoots, very little noise, (less than a 22 Long Rifle) a heavy thump when the Slug hits the target, just a tiny bit of kick, I love it.

I have not had a chance to get her on sand bags and see what kind of group I can get at 50 yards yet, when I do I will post the results.

When I shoot her, I will let a standard 45 ACP go in front so you can hear the difference.

I plan to attend a "Cowboy Action Meet", the first Saturday of March.

I think these Folks will love this little Rifle because it's so small, and quiet, yet, big enough to be respected.

Tristan · Post by **Tristan** » Tue Feb 23, 2010 8:40 pm

Tonight was the first time I clicked on this thread. Sat here and read it end to end.

Man! What a work of art!

The words fantastic, amazing and gorgeous are overused today, but in this case are simply adequate.

Charlie, thanks for sharing that with us.

Incredible.

- Tristan

samb · Post by **samb** » Mon Mar 22, 2010 1:14 am

Gorgeous Rifle. Read your story from start to finish for the first time tonight. Amazing talent, thanks for sharing.

Gaucho Gringo · Post by **Gaucho Gringo** » Sun Mar 28, 2010 5:26 pm

Today is the first time I found this thread. I read it beginning to end non stop. I am just speechless at this man's ability to create such a beautiful and functional rifle. He is a true old fashioned craftsman that seems to be a dying breed in America. I really enjoyed reading the entire thread and hope he builds many more projects.