LOL! Thank you Salt!! Just happened to log on for some relaxation. And happened on this post!

I will be posting my latest escapades shortly on a duffel cut repair... again! I was bothering the mill over the weekend, and managed to burn out the channel and begin shaping. But lets not jump the OP's question!!

Doc,
Well, I take pleasure in repairing these rifles. As I look towards future $$ as the rifles dry up, and also to conserve them for future shooting and collecting. What I am saying is that you may spend more to restore, than what it is currently worth. But it is worthy to restore one.

What you will need to do, is trim back the lower stock further into the barrel band. This will "hide" the cut/ repair... and is the exact location for most duffel cuts that I have experienced.

I use a mill/ drill and a 1/2 round router bit to create a barrel channel. It is darn close! I have noted that the barrels themselves are tapered so beware. I don't think it matters if there is more gap in the metal to wood on the sight end, but I have been repairing "late war/ last ditch" where the fit and finish don't always look great.

If you have acces to a router table, this is the next best way aside from the mill. I start with a 2x2x XX long chunk of walnut, or other suitable wood. You can find this stuff at Wood Crafters. I have used cherry before and Padauk. What ever you choose, go with a dried wood that is stable. No need to make a repair and have it crack off!!

After you have cut to length and secured it to the barrel it will be a long slow process shaping the section down. I typicaly use my mill to get the dimensions close, but have used wood planers before. When I am closer I go to rasps and bastard files.

The obvious solution is to simply buy a "new" used stock. These can go for good money (as there are many bubba'd rifles to restore). But it is up to you on whether you like tools and the process of restoration/ repair.

Whatch my threads and if time permits tonight, I will update my Arisakaicon saga on the next repair I am doing! If you have any other questions... feel free to PM me!

The big thing that I look for, is a wood that has a similar grain to what I am repairing, so the new sections isn't as obvious, in that regard.

The finish is going to be a problem. To my knowledge, duplicating the Urushi finish hasn't been done. Although many people like the linseed and tung oil finishes. Since the Urushi finish can cause allergies, and is hard to find in the US, I would recommend the tung oil route!