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I hope this info will be of use to some of you. I love learning new skills and shairing found knowledge. I undertook what to me was a scary task on one of my favorite rifles and wanted to show the process. I hope others find this helpful!


That being said here's your typical disclaimer: I AM NOT A GUNSMITH! If you choose to use any of this information on your own you do so at your own risk, to yourself and your firearm.Always wear proper PPE, gloves and safety glasses are a must. Crappy that I feel the need to say that :-/


So, I'm far from a gunsmith and this is the first real 'gunsmithy' type thing I have done other than shortening a barrel on a shotgun, and a bunch of 'bolt on' type mods.


I'm in the middle of building my 1895GS guide gun into a more ideal configuration for my wants. Part of this involved installing a magazine tube from an 1895SBL, which from he factory offered an increased capacity of 2 more rounds. 4+1 and 6+1 is a pretty big difference! In order to do this the mag tube stud had to be moved forward, this stud was mounted in a dovetail cut under the barrel. I did a lot of research and got a lot of guidance from a retired gunsmith on a local Nevada firearms forum I am on.


The tools I used were as follows:
-center punch to mark the location of the hole.
-Dovetail cutting jig from Dixie gunworks.
-standard ******* mill file I used a Nicholson file.
-double extra (XX) slim taper tringale ******* file - 6" length also Nicholson.
-chalk, plain old white chalk
-bench vise with a set of vise jaws to clamp the barrel.
-small level.
-hammer and drift punch to set the stud.


I purchased all of the above and a $3 section of black pipe close to the diameter of the barrel to make some test cuts in. I'm glad I did because this showed me a number of things I would not have anticipated. SpecificLLY that the jig is under sized. I had to move and re square the jig both forward and rearward to get the desired width of the dovetail.


The jig is also mega super raging hardened, to at least file hardness, so it acts as a 'stop' for your files and cannot be filed into. This means I did not need a safe side file. However you could make a safe side file easy enough. This also means that filing on the jig will dull your files. Just be careful of that.


Also the small triangular file I purchased showed up bent. It curved in several directions depending on how you viewed it. I ended up using this file just for the main cut then finished everything out with a different triangle file I had.


On the chalk. One of the tips that was given to me was to rub some chalk on the cutting side of the file before using. This keeps, or greatly reduced, the fine filings from sticking in the teeth of the file and kept everything cutting super smooth the whole time. Highly advised!


The below is copied from a post I made on another forum


I got it done using all the files I had on hand. Shame that the new one wouldnt work for the final cuts, but oh well. Sooooooo I leveled everything out like 400 times. I determined NOTHING on the rifle was square. The receiver, the flat on the bottom of the barrel, the first dovetail, the second dovetail, all were off from each other. I just went with the second existing dovetail, that was for the original mag tube, and leveled based on that.


Measured it out, traced the hole in the mag tube, used a punch to make a tiny dimple for reference and aligned the jig with that centered.




I started cutting. Amazing how easy it was when I had decent files. The crooked file helped me make the initial cut.










Initial cut sized to the jig:



I then moved it slightly forward and rearward re-levelling like 600 more times....and got this:




Amazing how my cut looks infinitely better than the cuts from marlin:





I kept making it sliiiiightly wider until I could get the stud to this point:



Then I turned my efforts to the stud itself and filed gently checking and checking until i could hand insert it to this point:



Then I drove it with a punch to the center of the barrel and done.



I looked at it from all angles and everything seems straight to me (this pic freaks me out even though the gun was completely disassembled AND i wasnt actually looking over the bore.... but thats a BIG bore!!!)



Reassembled, checked everything for function with some dummy rounds I have for reloading. Everything works, but that 6th round is TIGHT. I'm going to disassemble and see if its the spring being too scrunched up and long, or if the follower is bottoming out. Either one should be able to be shortened enough to give another 1/8th inch of play. It cycles reliably however, just that 6th round is tough to get in.


So, I present to you the 1895GSLM!!! 1895 Guide Stainless Long Mag!

 

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Great job! Strong work. Looks professional to me. Thanks for the pictures. I've never done that myself, but probably I will need to one of these days.

The trick to keep the filings out of the file is an old one, but very useful. BTW, the stuck filings are know as "pins".
 

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Another tip he gave was to never use a brush or 'file card' to clean the files. They will wear and dull the files. It's good business for the manufacturers to sell you a tool that will result in you needing to buy more files sooner.

He stated he crushed the mouth of an old 30.06 cartridge to make it flat, then would draw that across the teeth length wise to draw out the debris. The brass is soft and won't fill the file. I tried this and it worked great.
 

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I have cut a few dovetails without that jig, and man, I am going to Dixie to get one. Mine have always been for building black powder rifles. That jig is a thing of beauty. Congrats on your great work. Looks like you should have paid a bunch of cash for a gunsmith to put it in. Great work.
 

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That jig also works great for a straight edge guide for cutting off barrels 44 chop.jpg 021.JPG A couple worm clamps on either side help it from moving.
Good job.
 

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Nice work and a great write up, congrats.:beer:
 
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looks great!
 

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Excellent job, my fellow lever aficionado. Superb work.

On the Rockwell scale of hardness, "mega super raging" is off the chart! Hee.

An 1895 is in my future; I've caressed a few along the way to the acquisition of my pistol-caliber levers collection. I have a newfound appreciation for the straight-wall big bore cartridges, and now it is time to acquire the appropriate launching platform.

I am quite fond of the firearm you have created. Again: Well done!


:)
 
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Discussion Starter #11
That jig also works great for a straight edge guide for cutting off barrels View attachment 365962 View attachment 365970 A couple worm clamps on either side help it from moving.
Good job.
Unfortunately the outside edges of my jig are far from square. Easy to see with the naked eye. I was hopeful it would double as a guide for cutting barrels but I would need to have it squared up.
 

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Excellent job, my fellow lever aficionado. Superb work.

On the Rockwell scale of hardness, "mega super raging" is off the chart! Hee.

An 1895 is in my future; I've caressed a few along the way to the acquisition of my pistol-caliber levers collection. I have a newfound appreciation for the straight-wall big bore cartridges, and now it is time to acquire the appropriate launching platform.

I am quite fond of the firearm you have created. Again: Well done!


:)
Thanks! We refer to it as the shoulder mounted bowling ball launcher....haha.

I have a lot more work in the plans for this rifle, as time and money allow. Up next will be sights and slightly bigger lever, down the road will be WWG trigger and potentially some new furniture.
 

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Great write up and pics!!!
 

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TFine, job. I have cut a lot of dove tails, that jig would make it much easier. Have put off buying one for years. I use a hacksaw
jewlers saw and a dovetail file, not to mention levels and measuring tools just to get it set up. One thing you can never have to
many of are files, and good ones. The cheap files are only good to salvage the handles from.
 

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Thank you, thank you. I have been looking for this for some time. I just joined this forum today and I found your thread. I currently have a 1895 4 shot and want to put the larger tube on it. It looks like I will buy the tube for a 1895GBL. Again thanks for an informative thread. If anyone sees a flaw in this please speak up.
Thanks.
 

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Ordered one this morning.
Part number from Marlin is
F4026261 $27.33 Mag Tube
F406512 $7.65 Tube spring

Thought I would post to help the seekers find these.

Neal
 

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Thanks to Dr. Marneaus for giving me the confidence to do this mod. I have pondering for a long time on whether to try this or not.

I got the parts in today and after a few modifications to my bench for barrel support I started filing. I used 2 hose clamps on the taped wrap barrel to start the slot. Once I got down about .07 depth I removed the clamps and the support. I enclose a picture showing the old next to the new. You can see the old dovetail and I need to get some Blue in a Bottle but overall I am very pleased. It holds 6 + 1 and feeds and ejects great.
Thanks again. It was just what the Dr. ordered.

IMG_0101[1].JPG
 
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