No4 wood WIP

[tbonesmith]

I hope it's ok to post work in progress here. This is an rough no4 savage fore wood, that I'm repairing and then converting, along with the butt to no5 pattern. Should be good but a lot of work.
Here's the first installment, plugging the Ishapore screw...

Information

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[jmoore]

In progress is probably the best way to do it. Once you're done, there's not much to show except for the "pretty" bits. Here, you help teach, as well as learn from those who've done it before.

[tbonesmith]

Here the first repair is complete. The plug is dressed off and should colour up well with oil.
I've only sanded the area because the whole fore end will be cut down to a No5.

[tbonesmith]

I've cut the wood to rough length, and filled a lightening groove where the wood will end, to give a full barrel channel and end when shaped

[tbonesmith]

For this I've used a tennon saw, a block plane, a couple of chisels, a flat bottom spoke shave, some files and some blocks and clamps.
Having an original wood set and the band at hand were very handy.
I think once tidied up this should be pretty indistinguishable from an original all be it for the staining of the fore end.
Next up is the butt which I imagine will be the most difficult to get right.

[lee_enfield223]

what a great job !!!!!! and your pics are excellent !!!!

[louthepou]

Indeed, really great stuff mate - and it'll help me fixing a Jungle Carbine I have here, needing a new handguard. Thanks tbone,

Lou

[tbonesmith]

I've shortened the butt to the correct length, and inletted/fitted the butt plate and made as best i could the scoop for the sling. The butt needs some very minor further shaping top and bottom, but Ill deal with that as part of finishing and tidying up of the set as a whole.
Again tools used were a tennon saw, disc sander, fine dovetail saw, chisels and clamps.
The butt is not perfect, but I'm pretty happy with the result.
More to come.

[lee_enfield223]

the shape looks really good now that the butt plate has been fitted and when it's all stained the to the same color I bet it will look like a million bucks...

[tbonesmith]

I couldn't fit the butt plate perfectly, as I found out that a No 4 butt is not as full at the back end as an No5, however by patching the old sling swivel recess it's pretty damn close.
It was difficult to match the timber, being Poplar, Beech, and walnut, but also it's pretty close.
Most importantly it's done and gone, and I'm happy with the result.