I had this same challenge putting a Romo barrel into an Egyptian trunnion. There were several challenges. First, the barrel was not snug. I had to punch a ring of dimples to give it enough diameter to fit snug but not tight. Once I timed the barrel and head spaced it, I began to use the correct end mill. I had several problems. The barrel was harder than the trunnion. I know, soft Egyptian steel? No way. The end mill would drift and simply enlarge the hole. Also, there was enough looseness that the trunnion would slide off the barrel. This was driving me nuts.
Eventually, I managed to mill enough of a starting cut into the barrel. I pulled the barrel and used hand files to rough out an undersized slot in the barrel. I re-dimpled, reinstalled, head-spaced and timed it. I ran the end mill in again and it cut the correct-sized slot in the barrel. I eyeballed the results, checked headspace and then drove in a lubed roll pin. I check headspace again and was satisfied. I used cutting fluid and cleared chips as I went along. I had the drill pressed slowed down to the recommended speed. High speeds are not necessarily your friend.
Doc AV is the default setting for correct info.
Obviously I met the standards for a Kyber Pass built. Not proud but I believe the rifle is 100% safe. I will check the headspace repeatedly in the future. Once I had started I felt I had crossed the Rubicon and needed to complete the rifle. It will have all the ugly charm of a Bedouin shoulder arm.
I offer this not as a guideline, but simply as an example of what can and will go wrong. The experience has killed my desire to ever build with anything other than a already slotted barrel into a proper trunnion such as a Bulgarian barrel into a Bulgarian trunnion.
Last edited by AbueloMark; 02-06-2011 at 04:29 PM.
כד יְבָרֶכְךָ יְהוָה, וְיִשְׁמְרֶךָ. The LORD bless thee, and keep thee;
כה יָאֵר יְהוָה פָּנָיו אֵלֶיךָ, וִיחֻנֶּךָּ. The LORD make His face to shine upon thee, and be gracious unto thee;
כו יִשָּׂא יְהוָה פָּנָיו אֵלֶיךָ, וְיָשֵׂם לְךָ שָׁלוֹם. The LORD lift up His countenance upon thee, and give thee peace.