Fitting a new fore-end and it is fouling the front sight base

[Kiwi]

After reading and re-reading Peter Laidler's guide on how to fit a fore-end, I am fitting a 'new' Savage made fore-end to a No.4 mk1* Savage and have run into a bit of problem. The endcap of the fore-end just fouls the milled lug where the the front sight base fits on. Is this a common problem? Any suggestions out there to solve the problem?

I had thought that perhaps the rear section of the front sight milled base could be reduced with a lathe which would solve the fouling problem from the barrel, however when the front sight is attached to the barrel the front sight protector would no doubt foul the endcaps due to the the location of the groove for the front sight retaining pin meaning that the front sight base and protector would continue to protrude backwards and foul the endcaps of the fore-end and front hand guard. Could the retaining pin groove be re-cut further forward to stop fouling issues, or am I missing something obvious.

Information

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[Smellysniper]

Hi,Kiwi. I probably can`t help much with your problem but I thought if I did some measurements on my (non- Savage) No.4`s it may help a bit. The forends on both my rifles measure 707.5 mm from the endcap where yours is fouling to the centre of the reinforcing crosspin at the other end. I chose the pin as Datum as it is solid ,rather than the edge of the woodwhich is radiussed. The clearance at the front end between the front sight lug and cap is about 1.5 mm on one gun and 2.5 on the other. These measurements may tell you where the fault lies,in the wood or the barrel. It is encouraging that both my measurements were the same! The clearance wasn`t ,so there can obviously be discrepancies.
Is it possible that your barrel has been set back at some time? Unlikely I would think. My personal solution would be to shorten the wood at the front rather than remove metal on the barrel. This would mean the rivet holes would also have to drilled out and plugged then re-drilled and also the wood cut back and re-inletted at the back. Do -able I think. Another way perhaps is to remove a semi-circle of metal from the front of the cap large enough to clear the sight and allow it to float .Bit crude ,I think,but it would give the clearance needed. Nothing`s easy is it!. Regards, Tony

[stevebc]

How well does your forend fit at the butt socket end? Is it snugged up against the metal there? Pictures of the rear of the forend (while still on the rifle), and pictures of the draws would be helpful. If the draws were somehow larger than normal or had been added to as a repair job, that could move the whole forend forward.

[Simon P]

Ebay is full of No4 Fore-ends that originated from South Africa, a lot of them have poorly fitting end caps, I have had to refit a few recently because the front barrel band wouldn't fit properly.

This fore-end probably has the same issue, poorly fitted end cap.

[Ridolpho]

Kiwi: Your forend looks exactly like an unused Savage I have sitting in front of me. The metal is about 0.025inch ahead of the tip of the wood but at the rear it shoulders right up to the step in the wood which would have to be filed back to get your clearance. On mine the metal is 0.050inch thick so I believe I'd just very carefully file back the front flat area until you have enough clearance. Hit the filed area with some cold-blue to protect it. But, before doing anything, did you have any problems with the fitting of the new forend at the rear end? As stevebc says, a few photos of the fit at the back would help.

Ridolpho

[S-A-M3]

Yeah I`ve had this problem, drive the pin out and move the front sight base further forward,I`ve wondered over the years if the front site base was fitted last on new rifles to suit the woodwork?? If you check a lot of no4`s you will see the base is in different positions.

[ssj]

Looking down the main screw hole for the trigger guard does the hole look well aligned? ie not a bit far forward? Have the removed any wood off the draws? From the frustrated exercise i had/have in fitting the damn things I would expect an un-fitted forend to be too far forward as normal? Peter L?

---------- Post added at 11:21 AM ---------- Previous post was at 11:19 AM ----------

Ebay is full of No4 Fore-ends that originated from South Africa, a lot of them have poorly fitting end caps, I have had to refit a few recently because the front barrel band wouldn't fit properly.

This fore-end probably has the same issue, poorly fitted end cap.

I have one and it needs/needed a lot of hand fitting. Holes poorly aligned, barrel groove uneven etc etc.

[Thunderbox]

On a new forend, the rear face next to the butt socket often has to be slightly relieved - and definitely so if the forend has an asymetric bearing at first fit.

You can check by lining up the front trigger guard screw socket on the action with its corresponding hole in the forend.

[Kiwi]

I hope some of these pictures are of assistance.

[stevebc]

Thanks Kiwi- your pics show no problems that I can see at the rear end.