My machine tool talent is not good, and my lathe and mill are cheap Chinese. So when I need precision machine work, I turn to my buddy, to make this type of thing.
I stripped the finish off the staff and aperture, and then cleaned everything well, and blued the base, screws, staff and aperture. After some carding, the finish is mellow and not as shiny new as before, so it wont stand out on the old Whitney.
He built one of these for my #1 Remington Rolling Block also. It's in .22LR, and some idiot had drilled 4 different holes on the top tang for various tang sights. The outside farthest set was 2.25", which is Winchester. So I happened to have a Winchester base missing the staff, and he bushed one of his staffs to fit it.
This gun also had a buggered up front sight dovetail. Same person must have attacked it too. It had one dovetail about 3/4" wide, and then a 3/8" dovetail in the bottom of the larger dovetail! Ugly as sin, and I was afraid it would be a rebarrel. But my friend helped me out by cutting one large dovetail, and making a perfect filler for that. Then he cut a 3/8" dovetail in the filler, and we installed it with some JB Weld. The filler is almost invisible now, and the sight and barrel look original again!
