Barrel blank: http://www.e-sarcoinc.com/44-mag-1-0...stainless.aspx
center turned to .980 due to an off-center bore (a truly shocking development upon opening a $45 no-name barrel blank)
Another laser-cut lug:
What's the forend doing there? That'll be important later. Also important: The little breech alignment "ears" which serve to hold the rear face of the barrel EXACTLY in line with the rear of the lug to eliminate having to file on it - I've got my lugs to where they come out just a hair under length so I can shim it to fit rather than having to soot and file. This one took three layers of soda can aluminum to lock in perfectly.
Chambering and crowning are well documented processes, so I'll skip the details except to say quickdtoo's 445 reamer is sharp as heck and does a fine job.
(No barrel is complete until a fat shop dog has had a chance to sniff it)
A typically beautiful weld job from my gunsmith-recommended welder. All that gets ground off during fitting anyway, so it works.
Whole thing together with a new forend made for it:
Why's the forend at an angle? Because I'm still working out the kinks in this design, which is the coolest part of this build in my opinion:
I've incorporated the forend stud into the underlug, rather than welding it to the barrel. While the original purpose of this was to save me a welding step and make all the studs the EXACT right distance from the frame, it also serves to isolate the barrel from the forend entirely - the weight of the gun and barrel are not enough to force the forend into contact, though I can squeeze it there if I want to. On a barrel with any kind of taper it would work much better.
The advantages to this, aside from floating the barrel, are saving several steps in the aligning and welding of the stud, as well as making its location consistent so I'm not having to make new forends for every barrel anymore. Though I probably still will. It also stops the barrel from swinging too far open by bumping into the frame - I can still access the chamber, of course, but my extractorless barrels typically swing open much further than a factory one, and this one doesn't!
Haven't shot it yet, waiting on 445 brass and dies, but if it performs like my 357 it'll be a good one!