WESTERW PISTOL +22 CALIBER SINGLE SHOT Entire pamphlet Copyrighted by JACD Designs 1972 © % This pamphlet contains the pldas and instructions necessary te construct the Western pistol. ‘This pistol breaks open to load and clean and is locked closed with a lever that is located at the front oG.the trigger guard. Empty cases are automatically extracted when the gun is opened. ‘The hanner spring is a coil spring and is designed to produce extremely light sear forces in the full cock po- sition. This arrangement makey the gun easy to cock. A separate firing pin allows the use of a simple flat faced hanner. There is a half cock notch for added safety. The barrel may be made from an old rifle barrel or from a rifled blank conmonly sold for replac~ ing shot-out barrels. These can be obtained at gun supply houses. Should a rifled blank be chosen you can grind and file the blank or use a lathe to tum down and taper the barrel, The gun should be blued for a beautiful and rugged finish. JACO offers a hot bluing technique that 4s conparable in appearance and durability to those on factory made guns. One sheet of the plans shows a sectioned side view, a top view, and a sectioned partial side view which shows the barrel open and the hammer cocked. The other sheet shows details and patterns used for construction of tie various parts. These can be traced, cut and glued on the steel stock to assist in cutting out the parts, Before starting to cut metal it would be wise to read all the instructions and learn as much as possible about the pistol. This design has been refined by building and testing earlier uodels. In- tricate mechanisms requiring close fits have been eliminated without sacrificing inportant features. TE you build the pistol as instructed you will have a completely satisfactory weapon. Because we have no control over the materials you usa, the worknanship or possible use of the pistol, JACO witl Rot assume any responsibilicy for the pisrol. Most of the stock required is Cold Rolled Steel (CRS) and can be obtained at any steel supply house, Other than conmon toois like screwdrivers and files, etc., the only tools ueeded are a hacksaw, drill press and bench vise. Additional tools euch a3 a bandsaw and a lathe will make the work go easier and faster but are not esseatial. You may be tempted to alter the design to sult your own preference like a longer barrel or a differently shaped handle . JACO encourages these Innovations because they add to the satisfaction of building your own pistol. The builder, however, utioned against changing the interior mechanism without thorough study sinee this design has been proven. ‘These plans and instructions are not to be copied in whole or in part by anyone without written consent of JAC). 1 ~ MATERIAL ~ All the material for this pistol is soft cold rolled steel stock except for the springs which must be music wire. You will need a 1/8 x 5 x 5 inch plate and a 5/16 x 4x 6 inch plate, and rods, 3/16 dia. x 3 inches long, 1/8 dia. x 3 inches long and 3/32 dia. x 3 inches long, You will also noed sone music wire, .025 diameter about 4 inches long and sone .045 diameter wire about 36 inches long. In addition, several .062 dia. (16 gauge) nails will be needed for various pins. 2 ~ PATTERNS - Do not cut up your plans. Trace the outlines of the various parts and make paper patterns thar you can glue on the steel sheets. You can saw outside the patterns and easily rough out the parts. If you prefer, color the steel with red "Magic Marker" and scribe the outlines of the pacts on the steel, Plan ahead when laying out the parts so you can easily sav out the parts. 3 ~ Sav OUT PANTS - Saw out all che parts Jeaving a Little stock for clean up with a file. Drill holes at the locations show to give the inside radii as necessary. Donat. put in sear notches in 1 hammer. The Side Plates (28) § (31) should be clanped and filed together. Crieical dimensions auch as at the Tigger sear, hammer sear notches, latch face and extractor should be left oversize and Fistsned wt dasenbly> 4 = ASSEMBLE ON ONE SIDE PLATE (PARTIAL ASSEMBLY) - Mark the location of the three rivet holes in the Teteger Guard (22), two rivet holes in the liendle (13) end center punch. Drill each hole through with 1/16 inch drill, Merk the location of the two pin holes in the braech block, part 8 and drill through with a 3/16 inch drill, Locate the trigger guard on the right side plate in indicated position, clap together ond drill the three holes through with e 1/16 inch drill, Pin with 1/16 inch dias (16 gauge nail) pins, 11/16 inch long, Suze the handle against the ergger guard, clamp and drill ehrough both holes with 1/16 inch drill. Pin with 1/16 inch dia, pina 5/8 inch long. Locate Breech Block (part 8) on right side plate, part 28, as indicated, clamp: and drill the tvo holes through with a 3/16 inch @rill, Insert tyo 3/16 inch dia. CRS pins (11) (22) 5/8 inch long to hold the breech block and aide oleus Geen,5 = HAMMER - Locate, center punch and drill hole for Hanmer Pin (17) with a 1/8 dia. drill. Locate Hanmer (10) in its proper position on side plate in the partial assenbly. The face of the hivner should be flat against the breech block. Clamp and drill through with 1/8 inch drill, Pin with. 1/@ inch dia. C85 pin 5/8 inch tong. 6 = TercuHR - Locate, eenter punch and drill the wole for Trigger Pin Ga) with a U/# dia. drill. Locate Trigger (20) in Lt indleated location on the side plate in the partial assembly. The trigger have sufficient stock so that they can be filed to fit together. Clatp AL, Pin with 1/8 ich dia. CRS pin 5/8 inch long. Baal Ag! 7 = TRIGGER AND AAMMER OPERATION - Place hanner in the full cack position as indicated. File trigger gear cad hanner seat notch so that they engage at this point with an overlap cf about 0.020 inch. Place hazacr in the half cock position (ebout 1/9 inch off of breech block) and File balf cock notch ger sear at this point with an overlap of about 0.030 inch. The half cock notch vat in the hanaer so that the hammer does not catch in this notch when falling sear and hamper sear notch m ead drill through with i/8 inch dr: so that it engages b mist be recossed som from the full cock not 8 - YRAME ASSENSLY - Place left side plate on top of partial assenbly and clamp in the correct position. Remove one pin at a tise and drill through each hole replacing the pin through the entire assembly before starting the next hole. Merk and disassenble frame, Drill the external side of each rivet hole (five total) in the side franes with a 5/64 drill to a depth of 1/16 inch, Reassenble frane and trim the rivets to stick out 1/16 inch. Crush each rivet one at a time between the smooth jaws of a bench vise. 9 — BARREL - Obtain Barrel (3) from an old .22 Caliber rifle, 6 inches long or purchase a rifled blank from a gun supply house. If an old rifle barrel is used, the barrel will be tapered and the correct diameter and no lathe work is requited. If a rifled blank is purchased, the barrel should be ground or turned down to a dianeter of 11/16 inches. Tee muzzle end of the barrel is tapered starting at the middle of the barrel length co a dia. of 5/8 inch at the muzrle, Crown muzale end of barrel and square breech end of barrel, Drnw file a flat on barrel 5/16 inch wide by 2-1/2 inches long to fit part 26. Layout extractor, part 9, notch and file out as indicated. 10 - BARREL! BLOCK ~/ Layout and file extractor tang on Barrel Block, part 26, 3/16 inch thick as in- dicated. Lay out, center punch and drill screw clearance holes through as indicated with 13/64 inch erill. Counterbore the indicated hole with a flat bottom, 1/4 inch drill to the depth of 1/16 inch. Lay out the extractor slot and center punch the center of 1/8 inch dia, that will serve as the ends of the slot. Driil through with 1/8 inch drill. Remove the metal in the slot between the holes by drilt- ing as uany 1/8 inch diameter holes as possible. Finish slot by filing. Layout, center punch and drill latch pin, part 21, hole through with a 1/8 dia. drill, LL - ASSEMALE BARREL AND BARREL BLOCK ~ Clanp Barrel Block, part 26, on to the Barrel, part 3, in the indiceted position and mark lecation of threaded holes by drilling a center point in the barre! with a 13/64 dia. drill. Remove barrel block ond drill hole with No. 25 drill ta a depth of 1/8 inch. Use a flat, bottom Ne. 25. Grill and remove drill point from the bottom of holes. Tap holes with = No. 10 24 tap. Complete with bottoming tap to obtain maximum thread depth. Obtain two No. 10 ~ 24 round head steel screws, part 5 and 25, at any hardware store, 3/4 inch long. Cut each to the lengths indicated. Chuck into the defi] press and file neads to 15/64 inch tn dia, Position barrel block on barrel and aseenble with screws. 12 + ASSEMOLE BARREL ASSEMBLY Aub FRAME - Changer Loside edges of side plates where they will contact “partel-~ Slide: barred assembly —tuco-trame—pack -aprinst the breechblock and-down-on the-eide- photeo—— and clanp. Locate, center punch and dril? hinge pin hole through with 3/16 dia. drill. Make Hinge Pin, part 27, from a 3/16 dia, xod 5/8 4mch long and insert. 13 = LATC2 ~ Lay our, canter punch and drill a 1/8 dia, drill through Latch, part 23. Assenble larch into barrel block using a 1/B inch dla. Latch Pin, pert 4, 5/16 inch long. ‘File latch step 20 that it enga ez guard to hold the gun securely clerad, File where required to fit latch slot in erigger guard. Drill latch ag indleated with 1/32 inah drill for Lateh Spring, part 24. Make latch spring fron 0.025 iach dia, muse wire about 1 inch loag. Insert in latch, stake and bend to in~ dicated shape. 14 = EXTRACT should be ma OR - Lay out and file notch in Extractor, part 9, as indicated. The width of the notch ig to Zit the tang on the barrel bloc. ‘The extractor should be made to fit the barrel as perfectly as possible in the chamber area. Excess extractor material should be removed so that 1t does not extend beyond the breech of the barrel except for the extractor lug. . Ley out, center punch and drill extractor pin hole through with a 1/8 dia. drill. Locate extractor on barrel assenbly, clanp and drill through tang with 1/8 inch deill. Pin with 1/8 dia. Extractor Pin, part 21, 5/16 inch long. 15 - CHAMBER THE BARREL 2 drill and drill the breech end of the barral with extractor in position 0.77 inch decp. Open hole with a No, 1 drill to the same depth. . Drill to a depth of 0.040 dnch with a 9/32 dia, drill.16 - FIRING PIN ~ Mark the center of the barrel on the breech block. Marking is best accomplished by using red "Magic Marker" on the face to be marked and using a pointed brass rod 1/16 dach 4n diameter to reach through the barrel, Tap out breech block pins and renove the breech block from the frame. Measure up from the center 3/32 inch, center punch and drill the firing pin hole through with a 1/8 dia, drill, Moke Firing Pin, part 6, from a 1/8 dia. rod as indicated. The point can be produced by chuck- Ang the Firing pin tm a drifl press and shaping vith u file. File the retofning flat as indicated. | Re e breech block into the frame. Locate, center punch and drill retaining pin hole with a 3/32 e assembly. Assenble firing pin in position ond insert Retaining Pin, part 7. assenble dis. drill, through Lay out and fLle rear sight 1/8 inch wide 1/16 inch deep centered over the hore. 17 ~ HAMMBR SPRING - Wind Hamner Spring, part 14, vaing 25 codls of 0.045 inch dia, musie wire on a slotted wandrel 0.192 inch ia dia, Select a nih of this approximate dianeter and slot one end with hacksaw. Wind the colle tightly together adding a few more coils to allow for some spring back. Trim and {ile the ends square. Using pliers, stretch ond chen compress the spring back to solid height. The resulting free Length will provide zpproxinately the correct spring preload when assembled. Slip hawmer spring over Hanmer Spring Guide, part 15, and assemble into handle as indicated. 28 - TRIGGER SPRING ~ Trigger Spring, part 19, 1s nade from 0.025 inch dia. music wire 3/4 inch long. Disassenble trigger and drill @ hole in the trigger as indicated with a 1/32 inch drill. Insert the tels center punching around the hole. Bend spring as shown and reo install tra) 19 - FRONT SicaT - Front Sight, part 1, is made from 1/8 inch stock shaped as indicated, Drill a 1/16 inch dia. hole through front sight as shown. Carefully locare front sight cn barrel in position shown. Be sure that the sight is centered over the bore. Mark the hole lecation on the barrel. Center punch and drill hole 1/8 inch deep. Use epoxy and assenble front sight and 1/16 inch Front Sight Pin, part 2, ro barrel. ser spring and stake in location rs 20 ~ WOOD HANDLES - Wood Hondles, pert 29 and 30, are best made from walnut wood, Handles are fitted to the gun and thea shaped. It is inporcant that the wood fits the vee notch in che side plates, Drill handle for locating pin, part 32, using a 1/16 dia. drill. Insert a 1/16 inch dia, CRS pin 7/16 dnch Leng so that 1/16 inch protrudes from each side of the handle. Mark Vocation of location pin on wood handles by pressing them down carefully, Drill handles 1/26 inch deep with 1/16 inch drill at narked Tocation. Install wood handles using a No. 7 Elat head wood screw, 1 inch long modified as indicated in de- tail, part 16. The screw should be inserted fron the right side of the gun. The right handle should be drilled in the indicated location with 5/32 inch drill through. Gounterbore hole with 9/32 inch drill to a depth of 1/8 inch. Insert sctew and tighten by screwing into’ the opposite handle. Shape handles as indicated to obtain good fatr-in betveen wood and metal parts of the hendle. Wood handles should be finished with two coats of clear varnish with a Light sanding between coats 21 - STAMP ~ Using 1/16 inch stomps, Letters and nunbers, stamp your name, city and state and ".22 GAL.” ag indieated. 22 = FINISH - Finish file the gun with a smooth file all over first with the gun assembled to establish the proper "blend-in" of surfaces, then disassemble to reach all interior surfaces, Renowe all ex ternal surface scratches and scuff marks that vould marr the appearence of the finished gun. In finishing, it should be rewembered that a gun traditionally has square corners that are broken slightly to eliminate sharpness. Excessive rounding of edges ts not accepted gun practice. Wire brushing after snooth filing maxes a good servicable surface for a blued gun, intended for use in the field. 23 = THST FIRE - Clean the gun thoroughly with solvent and ofl gua mechanism with gun ail. Check gun for correct operatin of latch, extractor, hammer, firing pin and triggat. Chamber a live round, cock harmer, sight targee and squeeze trigger. Should th: ot fire, the firing pin is probably not striking the case with sufficient force, or not in the correct location ar with too large a mark. Compare your mark with that made from a factory made gun, thon make alterations and try again until sucerssful. 24 - SIGHT IN = Set up target and fire a five shot group. If che gun ehoots to the left, reno fvom the right side of the front sight. If the gun shoots low, remove stock from the cop of If the gun sheats high, remove stock from the top of the rear sight. The finel thickness of @ Eront sight should not be less than 1/16 inch. 25 ~ BWEING - The gun shovld be cleaned of grease by washing all steel parts with laquer thinner, The gua can be blued with any of the connercial cold bluing products but these tend to produce a super- Eicial coating that 1s not very durable, JACO has developed a hot bluing solution that can be accomplished on the Kitchen stove and provides as good a blue that is obtained commerically. See JACO brockure for ordering instructions. 26 ~ BOX - Select a good piece of White Pine 1 x 6 x 22 inches long. Cut board in half to form box and Lid. Dae outline of gun on the box and the opposite outline on the lid. Remove wood by chiseling so that half che gun fs recessed into the box and half in the lid. Sand and varnish box all over with Mar varnish. Select felt material of desired color and glue down inside box. Complete with in= BtMt Seen of einintuce bees, Whcace asl carek.,IOHS ZONIS “1V9 22 WOLSid NYALSAMWESTERN PISTOL 22 CAL. SINGLE SHOT