making a Colt/Keith style sight base and front sight

[Lonestar grips.]

some of you may remember my thread from last year on modifying my single seven. http://www.rugerforum.com/phpBB3/vie...p?f=3&t=223644

one of the things I did to it was to file down the stock aluminum front sight to resemble the front sight on Elmer Keith's No.5. since it was aluminum the only way I could re-finish it was to paint it black which with use would flake and look pretty cruddy.

so a few months back I got to thinking it would be really cool if could use a pinned in base on the gun so I could change blades whenever I wanted to. well one thing led to another and before long I wound up starting on a Colt flat top target style Base with a Keith style sight blade. rather than solder it on it would utilize a screw just like a regular single six front sight.



starting out I decided I wanted to do as much as I could with the materials I had on hand. after looking through my steel pile I settled on a railroad spike for the sight base. after cutting off a piece and squaring it up on the belt sander I used a dremal sanding drum to start cutting the channel for the barrel. once I had it roughed out I wrapped various grits of sandpaper around the barrel and continued sanding till the base sat on the barrel pretty well.











next I drilled the screw hole. starting with 9/64" for the screw body and then 3/16" for the screw head.







while that measurement was perfect for the stock Ruger screw, the head of the screw I got to use for this project ended up being slightly bigger. to fix this problem I chucked the screw up in the drill press, turned it on and used a file and fine grit sandpaper to take off some of the screw head diameter.









after Cutting the screw down I deepened the 3/16" hole to the proper depth for the screw.









next I used a needle file to mark where the sight channel would go. I used a bandsaw to cut the channel and then used several different files to widen it so a sight blade would fit.











all throughout the making of the base and sight blade I was having to make adjustments in order to get it as close to perfect as possible. one of those adjustments was I ended up deepening the sight blade channel. this caused the screw head to stick up. to fix this I deepened the screwdriver slot and then shortened the screw head till it sat flush.














next I used a 1/16" bit to drill two pin holes in the base.




once I got that done it was time to make the sight blade. again I decided to use the railroad spike. after cutting it out on the bandsaw I thinned it down using the belt sander.