Converting a South African FAL barrel to a bipod cut G1 barrel

[holescreek]

My first attempt at a conversion. I had a South African barrel that I picked up somewhere, it has decent rifling but some pitting. I figured that it would be a good barrel to practice on.

I bought one of the FAL demill receiver and barrel sets from Apex for the donor parts: https://www.apexgunparts.com/product_info.php/cPath/97/products_id/1744

At the top of the photo you can see the bipod cut section and the lug needed to retain the G1 flash hider. (Of course on this cut up barrel the lug was used for the bayonet)
http://i2.photobucket.com/albums/y29/Holescreek/FAL/EarlyFALtorched005.jpg

Here is the first attempt at grafting parts onto the SA barrel. I got a little chatter behind the split ring, but it should disappear after assembly.

http://i2.photobucket.com/albums/y29/Holescreek/FAL/FALbarrelconversion001.jpg

I'm not sure how others have been grafting the bayonet lugs on, here's how I did mine:
http://i2.photobucket.com/albums/y29/Holescreek/FAL/FALbarrelconversion002.jpg

I left the threads on this one, I can always take them off and sleeve over them later.
http://i2.photobucket.com/albums/y29/Holescreek/FAL/FALbarrelconversion003.jpg

I'm really interested in the methods that the pro's are using for these conversions/adaptations. I'd like to learn to do these things right.

[holescreek]

I had some time to fill in the shop today and decided to demill another demilled FAL barrel.

Started with the stub from Apex
http://i2.photobucket.com/albums/y29/Holescreek/FAL/FALbayonetband001.jpg

Set the stub in the lathe and tram it in. I used a Buck adjust-tru chuck which allows me to adjust the barrel band to run true in the lathe.
http://i2.photobucket.com/albums/y29/Holescreek/FAL/FALbayonetband003.jpg

Use a cutoff tool to remove the unwated parts,
http://i2.photobucket.com/albums/y29/Holescreek/FAL/FALbayonetband005.jpg

Drill the meat out of the barrel but don't get carried away with the drill size. I finished with a 17/32" drill:
http://i2.photobucket.com/albums/y29/Holescreek/FAL/FALbayonetband006.jpg

Set up a boring bar and start removing more metal, creep up in the .586" or whatever your barrel diameter is.
http://i2.photobucket.com/albums/y29/Holescreek/FAL/FALbayonetband007.jpg

Eventually as the barrel OD is reached the parts you want will come free. You'll be able to peel the unwanted metal away with some pliers.
http://i2.photobucket.com/albums/y29/Holescreek/FAL/FALbayonetband009.jpg

[holescreek]

You'll have these parts so far:
http://i2.photobucket.com/albums/y29/Holescreek/FAL/FALbayonetband010.jpg

You'll have to set the dovetail up in the mill vise and relieve it from the barrel section. This was the first of two setups:
http://i2.photobucket.com/albums/y29/Holescreek/FAL/FALbayonetband011.jpg

Now you have the 3 pieces you need:
http://i2.photobucket.com/albums/y29/Holescreek/FAL/FALbayonetband012.jpg

Once you get the barrel you're working on prepped you just slide the bipod cut and swivel section over your barrel and silver solder them in place
http://i2.photobucket.com/albums/y29/Holescreek/FAL/FALbayonetband015.jpg

After some measuring and careful setup, you'll have mounted your barrel in the mill and cut away a pad the same depth as your dovetail section. On my G1 barrel it had to be oriented in the correct spot on the barrel to properly locate the bayonet lug on the flash hider. Silver solder the dovetail section in place.
http://i2.photobucket.com/albums/y29/Holescreek/FAL/FALbayonetband014.jpg

[chili]

Great work. Wish I had that kind of talent.

[holescreek]

Thanks, but I think it's more of just a happy coincidence that my two favorite things are machining and gun building.

I just wanted to document the process I use in case someone else runs into the same problem I did. It doesn't require any specialty equipment that the average HSM wouldn't already have.

[chili]

Well to someone who does not have the machinery or talent (me), it looks like d@mn fine work.

[APEXgunparts]

WOW, that is some nice work!

We have had this discussion in the shop, but it sure is a lot more impressive to see the idea actually carried out to a sucessful build.

You have done a great job melding together two skills you are good at.

Richard@apexgunparts