Jungle Carbine Bayonet Lug Repair

im so happy mine came with everything intact - my big quest was a proper no5 bayonet , that does look like a nice solution , 

Well , I didnt want to give away to much ( being a newbie here 😁) but now that you have opened the door .....yeah ,I heated the "jolly🤬piece of 💩" smokin hot and ,yep , got the bfh swinging. I just got to the point that common sense was telling me to give it up. I actually started to think maybe its all one piece . 🙂

Yeah , I guess if they weren't to fussy about machining the mating surfaces smooth ( and they probly weren't ) heating the bejesus out of the flash hider and dropping it on ......would be like being almost screwed on , and heating it up that hot to get it off could be detrimental to muzzle dimensions and any heat treatment of the barrel steel .......maybe 

If you do manage to remove taper pins.

Hopefully you can see.. ultimately it is not worth the effort to rebuild a JC.

Here is a better picture of what helped me remove the flash hiders, The steel block has a 16.5 mm hole to accommodate barrel.  The punch is 9mm (very important size).  Very little surface to surface contact. Just 0.5mm per side.  The compromise is not to overload the punch in the press an deform the crown.  So as long as the pins are removed completely, and you get it quite warm or hot, they do come off, as you would expect, with no damage.  Just as a side, I have been doing this type of problem solving for years.  And it still took me over a year to get all my ducks lined up in a row to get it done.  The main reason for my post is just to show that it can be done.  I did have access to a wire cutter for the profiles. and also, a CNC machine for adding the details to the profiles. also welding and machining equipment. But if you were of a mind, you could farm this stuff out.

I originally thought of that too, a few years ago, when I found myself needing some and couldn't get them.  Being a machinist by trade for the last 30 years, I have a reasonable understanding of the process required to make these.  Originally made by a process of forging, punching, pressing, broaching, machining, on a grand scale.  Today would be made in small quantities to order, machined from round bar, with as many operations as possible done in a 5 axis CNC machine, possibly last operation being wire cutting the dovetail.  I really don't think you would get much change from $400 - we don't have thousands of people needing these - hence why I ended up doing it my way - at a cost of zero (for me) (excluding my time spent) - just as an experiment I could try sending the solid 3D model and drawings I made to China and India for a quote.  I'm hearing that's what some people do nowadays. 

Shamu wrote: I wonder could you fabricate JUST the bayonet lug & silver solder it to an existing flash suppressor housing? You can safely silver solder front sight ramps without damage to the barrel but I'm not really sure of the strength with a bayonet attached?