I finally made some progress on this project.
I wanted to replicate a little more rare gun, than just the average Dance. (If you can call a Dance average!) Our very own Sourdough sent me some pictures from his Dance book, and one of them jumped right out at me. A Dance with a shorter barrel. From the factory! So that is what I set out to do. Here's the original.
With the help of our newest member here, Marshal Will Wigham, we determined that the factory gun has a 6" barrel on it. So out came the hacksaw and jig, and I eliminated the unwanted length. I also cut the loading lever down to match.
Now that everything is the correct length, I needed to cut a dovetail for the loading lever latch and a groove for the new blade front sight. Since I don't have a fancy dovetail jig like some of your guys, I had to get inventive.
First I measured the original dovetail with my caliper and transferred the measurements to the barrel with a small machinists square and a scribe. Then I outlined the marks with some aluminum tape. It looked like this.
Now we're ready to cut. Using a brand new hack saw blade. I made a series of cuts, very close together and right down to the tape.
After the cuts were made, I used a small punch and hammer to knock the leftover metal out of the channel. It breaks right off. Then I just cleaned it all up with files and used a triangle file to cut the dovetail in. It wasn't that hard at all.
Just a few measurements and quick swipes with the file, and the latch was tapped in. As for the slot for the sight, I did it the same way I did on the other Dance. I measured and marked it with the little square and scribed where I wanted it. Then I used two Dremel cutoff wheels stacked and cut the groove. Very slowly and carefully. I fashioned the sight blade out of brass stock, and soldered it in.
Now I just need to finish up the end of the loading lever, so the latch components can be re-installed on the shorter lever.
Here's how it looks all together as of now.
It's nowhere near finished yet. There's lots of plans for it still. So stay tuned to see what happens next.