False Muzzle

[Nuclearcricket]

Rick, somewhere, sometime in my past and I just don't remember where I had read an article on how to make a false muzzle for a pre-rifled barrel. The best I can remember is that you cast a plug in the muzzle end of the barrel and then marked and parted off the end that will be the false muzzle. you do not cut through the plug. Once parted off, the mating ends were squared and the false muzzle put back on the cast plug. This assures that the rifling lines back up and then your alignment pin holes are drilled. If a round barrel is used, not a problem but if its an octagon barrel then the flats will be off just a touch but that shouldn't really be a problem and the false muzzle could be turned round to eliminate the flats and just look pretty. One thing you would want to make sure that you did not do is drill the holes in a square pattern, you would want one or 2 of the holes off so that things will only go back together one way and one way only.
I know this isn't much of a detailed description but it may be a place for you to start.
Sam
P.S. Had a thought after I posted the above. Another possible way of doing it would be to have the end of the barrel cut off in a wire EDM machine, if you can find one with a tank big enough to handle the length of a barrel. Yes it would cause a very slight misalignment but at the most the cut should only cost you about .020 of barrel material the amount of rotation in that length wouldn't be noticeable. I will set down here later on once all of the morning brain fog has cleared and fire up the calculator and figure out just how much of a misalignment it would be to loose .02" for the cut off.