'rcathey' - Was that your photo of the 'stressed' .30-40 cartridge-case, that I took the liberty of using? (Thanks, for posting it on the KCA site, long ago).

What kind of "barrel-vise" do you use? (With the "clocked" or "timed" threads, original U.S. Kragicon barrels seem to be easily switched or replaced).

FWIW - Maybe the OP's front-sight blade was left off as a warning "not to fire", because of an altered barrel/chamber?