40 Caliber Volcanic Rifle,

Charlie · Post by **Charlie** » Fri Nov 20, 2009 11:04 am

What a Sweet Little Rifle!

Trim, Slender, Beautifully proportioned, Sexy Little Action, fun to look at, and fun to play with.

Not only that, this is where it all began, "Lever Guns" that is.

Below is a 21" Barrel Carbine.

The original Volcanic shot a short little Bullet called the "Rocket Ball", it was less than .650 Lg. and had very little power, but this Rifle had the genes to become the legendary Winchester.
It goes like this;

The Volcanic was enlarged to become the "Henry",
The "Henry" was improved to become the "Winchester 66"
The 66 was improved to become the "Winchester 73"
The 73 was enlarged to become the 76.
And then Mr. Browning came along with a much stronger, smaller action, and replaced the "Toggle Link System", invented by Mr. Smith and Mr. Wesson, which was used in the Volcanics through the 76.

Above is my design, based on the Toggle Link System. My design is stronger than theirs, and easier for me to build.
While designing this gun, I tried to copy the original dimensions and proportions. I do not have access to an original, so I have had to "scale" photographs to come up with what I have.
The first problem I came to was this Little Action would not shuffle and shuck any available cartridges except the "22 Short"! This did not excite me so I designed my own "Wildcat 40". I will describe it to you later.

This is not a "Kit", or a modification of another "Lever Gun" I will not be using purchased parts, or parts from other Guns. I will use a purchased Barrel Blank from "Douglas" (40 Caliber, 1 in 14 twist) cut it, mill it, thread it, and chamber it for this Rifle. Everything else, including the Springs and most of the Screws, I will make from scratch.

I do this for fun, nothing else, I do not build guns for other people, or plan to go in to the business someday.

I am here to share Guns and Friendship with you Guys.

I hope you will enjoy this build.

Later,

Charlie

gamekeeper · Post by **gamekeeper** » Fri Nov 20, 2009 11:46 am

Fantastic! Thanks for sharing your incredible hobby with us all.

Ben_Rumson · Post by **Ben_Rumson** » Fri Nov 20, 2009 1:00 pm

This is a neat project.. I'm pretty sure I've read about this somewhere else on the net.. The 40 cal ammo rings a bell..

Buck Elliott · Post by **Buck Elliott** » Fri Nov 20, 2009 1:14 pm

Ben_Rumson wrote:This is a neat project.. I'm pretty sure I've read about this somewhere else on the net.. The 40 cal ammo rings a bell..

Same here ...

Keep us posted, Charlie.

Post by **Ysabel Kid** » Fri Nov 20, 2009 1:30 pm

Please, please, PLEASE take lots of photos along the way. This is going to be a fascinating project to watch!!!

Buck Elliott · Post by **Buck Elliott** » Fri Nov 20, 2009 1:38 pm

Ysabel Kid wrote:Please, please, PLEASE take lots of photos along the way. This is going to be a fascinating project to watch!!!

Just make sure you include your feet in a couple of 'em...

JReed · Post by **JReed** » Fri Nov 20, 2009 3:15 pm

Yes don't leave us out on the details. I am most interested in seeing how this project comes together for you.

Kansas Ed · Post by **Kansas Ed** » Fri Nov 20, 2009 3:22 pm

I for one, might be interested in the .22 short version. I think one in the short would be a fantastic squirrel rifle. And we sure do have limited selection of a clean line high quality .22 short lever gun IMO.

Ed

Cliff · Post by **Cliff** » Fri Nov 20, 2009 3:51 pm

I suppose if you wanted to stick with a rimfire, you could build it in a 41 remington rim fire used in the old derringers. Still plenty low powered. I will be quiet now. Good Luck.

Bis · Post by **Bis** » Fri Nov 20, 2009 4:11 pm

What a great project. Please post pics

kimwcook · Post by **kimwcook** » Fri Nov 20, 2009 8:12 pm

Cool. Can't wait to see the final project. Hope you don't pull too much hair out along the way or you're like me and don't have any left to pull.

Post by **Chuck 100 yd** » Fri Nov 20, 2009 9:00 pm

Cant wait....... Can you post drawings of the parts or sell drawings for those wanting to try their hand at fabing one up? There are several here that are handy enough to do it.

dsmith512 · Post by **dsmith512** » Fri Nov 20, 2009 9:04 pm

Like many here, it seemed like I heard of a project like this before with a 40 caliber round. I dug through the archives and found a thread posted by Old Ironsights about a Homebuilt Volcanic

http://www.levergunscommunity.com/viewt ... w=previous

The round was a modified S&W 40.

Homemade Volcanics just seem way Cool

Griff · Post by **Griff** » Fri Nov 20, 2009 9:20 pm

or "2 cool"

pokey · Post by **pokey** » Fri Nov 20, 2009 9:29 pm

Griff wrote: or "2 cool"

maybe, three cool

Charlie · Post by **Charlie** » Fri Nov 20, 2009 11:11 pm

dsmith512 wrote:Like many here, it seemed like I heard of a project like this before with a 40 caliber round. I dug through the archives and found a thread posted by Old Ironsights about a Homebuilt Volcanic

http://www.levergunscommunity.com/viewt ... w=previous

The round was a modified S&W 40.

Homemade Volcanics just seem way Cool

I am the builder of that Pistol.

I documented that build on another website that required money to be a member.

Over here, it's free!

Enjoy it my Friends, that is my only reward.

Let's just have some fun doing things that have not been done before.

Later,

Charlie

Ben_Rumson · Post by **Ben_Rumson** » Sat Nov 21, 2009 12:30 am

Well Charlie, now that you have it figured, here's a pick that would have made things easier to scale from..Easy to see the changes you made to the toggles now that I finally saw your pistol from where you originally posted.. cool!

soon 2 retire · Post by **soon 2 retire** » Sat Nov 21, 2009 8:40 am

Charlie,

I find this really interesting. I am curious about your background, machinist by trade? Self-taught? And will you please tell what kind of lathe and mill do you use?

Bob in NE Indiana

Charlie · Post by **Charlie** » Sat Nov 21, 2009 8:49 am

That picture was taken by a well known Gunsmith named "John Taylor", he had this gun in his shop doing some restoration.

Yes, that would have been a great help, but I didn't have it at the time, so I did the best I could.

About the Cartridge that I'm shooting,

It has been correctly noted that this gun will shuffle, shoot, and shuck the "22 Short", also the (sometimes available) 41 Derringer.

Even though these are an improvement over the original "Rocket Ball", I am not very impressed with either of them.

The actual caliber of the #2 Rocket Ball was .41. So that is why I set out to develope my own cartridge.

I figured it like this; if I can't build my own cartridge, then I'm not gonna be able to build this gun.

I do agree somewhat with the Guys that would want this gun in "22 Short", it's not for me, but it would make a nice little Squrrel Gun.

I shortened a 40 S+W case to .550, I reamed out the inside to accept the Bullet. The Cartridge shown is loaded with "Berry's 135 grain" copper plated bullet being shoved out of an 8" barrel at 1020 FPS in front of 4 grains of "Bullseye". I have fired this Cartridge out of a 25" barrel and lost nearly 100 FPS ! I don't like this load as it does show signs of pressure. I have been shooting a 140 grain cast bullet in front of 3.5 grains of "Power Pistol", here I am getting 890 FPS, and visual inspection shows only moderate pressure.

The Cartridges shown above are shown in compairson to "22 Long Rifles"

HEY I LIKE THIS PLACE.

There is a lot of enthusiasm here.

Overlook my spelling please.

Later Charlie

Charlie · Post by **Charlie** » Sat Nov 21, 2009 8:54 am

soon 2 retire wrote:Charlie,

I find this really interesting. I am curious about your background, machinist by trade? Self-taught? And will you please tell what kind of lathe and mill do you use?

Bob in NE Indiana

I am a Mechanical Engineer and Machine Designer. I was a Machinist a long time ago.

I have a "Bridgeport" and a "1955 Tool Room Hendy". I also have a small, but very robust "CNC Tabletop Mill", which I built myself.

kimwcook · Post by **kimwcook** » Sat Nov 21, 2009 9:08 am

Again, cool. Sounds like this is gonna be fun.

TedH · Post by **TedH** » Sat Nov 21, 2009 9:15 am

Keep us updated with pics as you progress.

Charlie · Post by **Charlie** » Sat Nov 21, 2009 12:43 pm

In all my research, I have found this book to be the most informative.

That's a Beautiful 20" Volcanic on the cover.

Charlie · Post by **Charlie** » Sat Nov 21, 2009 12:47 pm

OK, let's get started.

This is a basic Barrel Blank by Douglas. It is 1.300 O.D., I will put it between Centers and turn it end to end, 1.25 and then cut off each end to have a barrel 25.09 Lg. (the rifleing is not perfect at the very ends is the reason you cut off both ends.)

Charlie · Post by **Charlie** » Sat Nov 21, 2009 12:54 pm

Useing a Center in the Tail Stock, I single pointed this Thread. It is 11/16 - 20 UN X .875 Lg.

Charlie · Post by **Charlie** » Sat Nov 21, 2009 1:26 pm

Turning the barrel around and once again using the Tail Stock Center, I turned this Muzzle Extension. That is a 11/16 - 20 Left Hand Thread you are looking at here, the extension is .624 Dia.

Charlie · Post by **Charlie** » Sat Nov 21, 2009 1:35 pm

Not much to see here, but this is to become the Magazine Block. It has a drilled and reamed hole through it and that 11/16 -20 Left Hand Thread cut in one end.

We will thread this over the Muzzle Extension, and take the assembly to the Milling Machine where they will get their Octogon shape, also a .281 Radius trench milled the intire length along the bottom.

Charlie · Post by **Charlie** » Sat Nov 21, 2009 2:41 pm

I like using a double vice setup when milling long bars like this.

This Barrel wants to have a slight taper, so I put a .040 shim under the Muzzle while milling the flats.

This is a picture from a previous Barrel, but the Idea is the same.

Charlie · Post by **Charlie** » Sat Nov 21, 2009 3:04 pm

Hey Guys, I can't continue like this. I have been here over 4 hours today trying to post these pictures.

Photobucket won't let me resize my pictures and this sight will not accept the pictures directly from my old camera.

I had tried some other photo storage sites and could not make them work for me at all.

Maybe I can figure this out some day.

Meanwhile, I got a gun to build.

OK, I'm on a more powerful computer this morning and things are working for me.

Remember I had threaded the Magazine Block on the Barrel extension and put the intire assembly in the milling machine to mill the outside flats and magazine trench? Well here it is off the milling machine.

JohndeFresno · Post by **JohndeFresno** » Sat Nov 21, 2009 4:17 pm

Very interesting stuff, Charlie. Thank you for the effort, info, and pix!

Post by **Chuck 100 yd** » Sat Nov 21, 2009 6:24 pm

Very good Charlie. Keep it coming as you can Please!!

Buck Elliott · Post by **Buck Elliott** » Sat Nov 21, 2009 6:32 pm

Photobucket will allow you to resize -- at least that has been my recent experience...

Keep takin' pictures. I'm sure a way will open up to post them.

Charlie · Post by **Charlie** » Sat Nov 21, 2009 6:57 pm

Buck Elliott wrote:Photobucket will allow you to resize -- at least that has been my recent experience...

Keep takin' pictures. I'm sure a way will open up to post them.

I know Buck, that's the way I got the pictures above to show up. After 6 to 8 trys it would finally let them down size. Now it simply don't work for me anymore.

Kansas Ed · Post by **Kansas Ed** » Sat Nov 21, 2009 7:18 pm

I always resize before Photobucket Using MS Picture Viewer. What program is used on your computer to view the pics?

Ed

Charlie · Post by **Charlie** » Tue Nov 24, 2009 8:05 am

Here is a close up of the breech end.

Charlie · Post by **Charlie** » Tue Nov 24, 2009 8:07 am

Here is the Magazine Block removed from the Barrel Extension.

Charlie · Post by **Charlie** » Tue Nov 24, 2009 8:15 am

The next thing we need to do is solder the Magazine Tubes underneath the Barrel. I will get pictures and explain how I did it , soon to come.

Later,

Charlie

Ben_Rumson · Post by **Ben_Rumson** » Tue Nov 24, 2009 11:00 am

Sweet... Really kook forward to THIS

post!

Charlie · Post by **Charlie** » Tue Nov 24, 2009 4:49 pm

Those Magazine tubes were made from 5/8 OD, X 7/16 ID, AISI ~ 1018 Mechanical tubing.
I cut them to length, 5.030 for the Magazine Block, 19.281 for the Barrel. Turned the OD to Ø.562, and we are ready to solder.
With some good clamps and holding your mouth just right, you can get a good soldering job.
I made the clamps shown here from 1/4 X 1 Flat Bar
I prepared the parts,
fluxed them,
heated them and applied solder,
spread the solder with steel wool over the area that wants to be mated with the other part,
(both parts)
clamped them together with the clamps,
layed short lengths of solder (.38 Lg.) every 2" or so on the joint.
heated the entire Assembly from underneath until the solder melted and ran down into the joint.
Added a little more solder to the joint.
Let them cool, removed the clamps, and spent the rest of the afternoon cleaning them up.

I will take some pictures of the Soldering Job next and show you what we got.

Later,

Charlie

Charlie · Post by **Charlie** » Tue Nov 24, 2009 8:03 pm

Here she is, all soldered together, close-ups to follow.

Post by **Chuck 100 yd** » Tue Nov 24, 2009 8:23 pm

WOW ! That is so cool ! Cant wait for more.

Charlie · Post by **Charlie** » Tue Nov 24, 2009 8:35 pm

Muzzle.

Here is a picture of the original Volcanic muzzle, showing the Locking Key and rotation limiter.

Charlie · Post by **Charlie** » Tue Nov 24, 2009 8:39 pm

Breech.

Charlie · Post by **Charlie** » Tue Nov 24, 2009 8:44 pm

Here is the Magazine Block removed from the Barrel.

I got some stuff to talk about here concerning that Left Hand Thread, I will go in to it tomorrow.

There is a protruding tab under the Barrel that is pushed toward the Action by a long spring. this Spring pushes the Cartridges back into the Action where they are lifted up and shoved into the Chamber by the Bolt. To load this Gun, this Tab is pulled up into the Magazine Block, compressing the Spring in front of it, the Magazine Block is un-locked and rotated Clockwise about 35º exposing the Magazine tube for droping the Cartridges into it. This Rifle with the 25" Barrel will hold 25 shots and one in the Chamber.

On the original "Volcanic", and "Henry", the Magazine Block was held on the Barrel extension by a collar which had the front sight mounted to it. This collar did not rotate but allowed the Magazine block to rotate, it also had a recess milled in the front that served as a stop to limit the rotation of the magazine Block.

In keeping with the method and spirit of the original, my Rifle opperates the same as theirs, however, I have designed a different way to retain the rotating Magazine Block and limit the rotation. My Magazine Block is held on the Barrel extension by this Left Hand thread. The thread is timed so that when it is bottomed out, the tubes line up with each other. The reason for the Left Hand thread is so that as the Magazine Block is rotated Clockwise, it backs away from the Barrel instead of tightening into it.

Notice the tube has had a .25 Lg. plug pressed into it, blocking off the front. It has also been bored out to Ø.500 to accept the Locking Sleave which I have yet to make, or explain how it works.

The next thing I will do is mill that Slot along the underneath of the Barrel, and then make the Lock Sleave, then wind a spring and make the Cartridge Pusher.

Later my Friends,

Charlie

kimwcook · Post by **kimwcook** » Tue Nov 24, 2009 8:49 pm

This is so cool, Charlie. Very clean looking work. I love watching skilled work. It's inspiring.

Post by **Ysabel Kid** » Tue Nov 24, 2009 9:47 pm

kimwcook wrote: It's inspiring.

That sums it up nicely!

JReed · Post by **JReed** » Tue Nov 24, 2009 10:51 pm

Awesome work Charlie you are indeed gifted.

Can't wait to see the rest of this gun.

Alan Wood · Post by **Alan Wood** » Tue Nov 24, 2009 10:55 pm

Thank you for writing this up with Pictures Charlie. Looking good there!

Griff · Post by **Griff** » Wed Nov 25, 2009 3:55 am

Excellent. Just what you've done so far is way over my head... But, still neat that an average (yeah right, genius is more like it), can do this stuff!

Charlie · Post by **Charlie** » Wed Nov 25, 2009 8:00 am

Hey Guys, thanks for the nice compliments and expressions of appreciation.
This encourages me to continue.
After all, I would not do this if nobody was interested.

Go back and read where I explained how my Magazine Block works, I think you will like it.

Later,

Charlie