Interwar 1903 Spring SA Star marked barrel, fake of authentic?

Please find below a detailed and challenging question of authenticity. I ask those interested with informed expertise to read the entire rather long inquiry below.

I have a number of Interwar 1903 Spring SA Star marked barrels. One of them (a 1922 SA barrel on a late 1922 SA receiver) has no Star Gauge Data Card number stamped on the barrel. The star mark on the muzzle of this 1922 barrel while viewed both by eye and under a good loop, matches all of the other star markings in size, features, location, and with the slight wear typical over time. Over the years I have seen a number of barrels marked with a fake star. The many fake star marks Ive seen never look anywhere near correct. This one is dead on correct. However, the lack of a Star Gauge Data Card number stamped on the barrel is noteworthy.

Is there any history or expert information of other star marked SA barrel made within the correct dates which looks otherwise authentic that DOES NOT have a Star Gauge Data Card number stamped on the barrel?

Ive seen a lot of comments on Star barrels on this site and others and frankly many are misinformed. I am looking or expert information, if there is any on this topic.

I am well informed of the history of SA 1903 barrel manufacture, the nature of star gauging and the purpose of the Star Gauge Data Card number. It was a quality inspection procedure taken from one barrel per every X numbers of barrels to verify that the manufacturing process parameters were still all under control and limits.

The number of barrels made between a single star gauge inspection was determined by a selected AQL level. It is based upon statistical number of barrel taken at regular intervals within a total quantity of a given production batch (i.e., between shifts, or between the size of raw barrel lots, or between maintenance downtime of the production line or equipment). AQL sampling became common during World War II. Sampling plans, such as MIL-STD-105, were developed by Harold F. Dodge and others and became frequently used as standards. AQL sampling is still used today as a tool for quality control, but has largely been supplanted by setting Cpk and Ppk levels (more modern quality tech jargon).

As an expert in machine and mechanical design and manufacturing processes and practices in multiple industries since 1979 I have well versed in manufacturing and quality practices and work instructions. I know from sometimes bitter experience that there are always, or at least often variations to compliance of written manufacturing and quality processes and work instructions either by omission, poor training, haste, etc. The so-called "low number" 1903 SA and RIA receivers was, in part, a result of variations to compliance of written manufacturing and quality processes and work instructions.

Based upon my experience the inspection work instructions would basically be:
1) the barrel was pulled at the preset interval,
measurements were taken,
2) the measurements recorded on a card,
3) a card number was taken from a master card number registry and assigned and written on the card,
4) the card was attached to the barrel, and
5) the card number was hand stamped in the barrel and if it passed,
6) the barrel returned to inventory or to the quarantined batch until the batch was approved.

There are clear precedence for examples of these types of errors (e.g., duplication 1903A3 serial numbers). However, I have come to learn that there is a general consensus that the lack of a Star Gauge Data Card number stamped on the barrel of a barrel with "Star" marked on the muzzle indicates that the star mark MIGHT be a fake. I nee to know if it MAY also still be authentic.

So, to reiterate my question, I am looking or expert information and/or history that:
a) this 1922 barrel is either an example of an authentic star marked and measured barrel that was never stamped with the card number, OR
b) this barrel is a fake star marked barrel despite the virtual duplication of the mark itself when compared to dozens of Star gauge and marked barrels considered authentic?

I am unable to comment on the authenticity of your star-marked barrel sans star gauge record number. I can, however, point out that January, 1922, was the beginning of a new series of star gauge record numbers that were marked in a single line and preceded by the alphabetical letter "B", the first of which was simply "B". By 1923, the B-prefix barrels became exclusive to NRA Sporters. I will also point out that NRA Sporter barrel star gauge record numbers were usually stamp midways of the barrel and sometimes on the bottom of the barrel. So I recommend that you examine the barrel around the midpoint for a 1 or 2-digit number preceded by the letter "B" and perhaps a hyphen.

I concur that star gauge inspection was used to control and confirm the quality of barrel manufacture. But barrels exhibiting a star gauge record number were actually barrels specially manufactured for the National Matches.

J.B.

Hi John, and thanks for responding. I mentioned in my post that the barrel DOES NOT have a stamped with the card number. Im still seeking insights if this happened now and then. No factory processes are without missed or non-compliance events, however rare. Ive been in manufacturing as an engineer since '79 and many years in the defense industry and I know this for a fact, sadly...even in these "modern times". Ill try to attach a pic of the star mark, but that was not the question. The star mark is virtually identical to a number of star marked barrels that do in fact have the card number stamped on the barrel. I believe that this barrel is an authentic star marked barrel but the marking of the barrel with the card number was overlooked. However, Id like to hear if any one else has seen any other examples of this production anomaly. If not then I can believe what I want but unless I can find some written verification from those times that this happened now and then I will never really know for sure...or will at least be unable to prove it!

As to the specific use of star barrels I believe the converse is more accurate...all National Match rifles were fitted with Star marked barrels. However, there were far more star marked barrels made than needed for the requisite NM rifles and estimated need for NM replacement barrels (some match rifles were re-barreled yearly). The total number of star marked barrels was solely driven by the pre-set AQL sample plan in place with the bore gaging inspection method used from '22 thru '39. The AQL level that was selected determined the number of barrels pulled from the line after a given number of daily or weekly barrel production. As long as the line was making SA '03 barrels there were star barrels marked at a proportional rate. That is the nature and specific, and involatile requirement of MIL-STD-105. Otherwise the production line would not pass regular process audits also in place at the time and production would stop until the line was brought back into compliance with the MIL STD.

I am unable to comment on the authenticity of a star-marked barrel sans star-gauge record number. I do not recall having seen one. But I concur that the workers were human and errors/oversights were made. Certainly I have seen errors/oversights in other aspects of M1903 manufacture.

I concur that star-gauging was used as a quality control measure much like you describe to ensure the quality of service rifle barrel bores. But service rifle star-gauged barrels were not marked. Only barrels specially manufactured for National Match, Special Target, and Sporter rifles were marked with the star gauge record number.

J.B.

Sorry for the thread drift David but I just wanted to mention that we're practically neighbors, I live 7-8 miles North of you in Corinth. When you mention years in the defense industry you aren't perchance a fellow former T.I./Raytheon alumnus are you?

Regards,
Derek