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stefang
11-02-2014, 05:12 PM
Hi!

I was not sure if I should put this here in General or in Gunsmithing, but as I am not actually building a gun, just a miniature of one, I went for General.

I always wanted to make a miniature of a firearm and as I found the drawings from Mr. Benson and just went for it. I started making single parts to see if I was able to do it.
I decided on a scale of 1:3 as this seems a common scale for miniature guns.

First thing I got my hand on was the magazine catch. Most of the machining was done on my G1l Pantograph machine:
http://gtwr.de/web/wp-content/uploads/2014/09/pro_redux_5.jpg

The almost finished magazine catches, before parting off:
http://gtwr.de/web/wp-content/uploads/2014/09/pro_redux_15.jpg

After parting off:
http://gtwr.de/web/wp-content/uploads/2014/09/pro_redux_17.jpg

Then the backside was drilled out:
http://gtwr.de/web/wp-content/uploads/2014/09/pro_redux_19.jpg

And the slot for the locking pin was machined:
http://gtwr.de/web/wp-content/uploads/2014/09/pro_redux_20.jpg

The finished magazine catches:
http://gtwr.de/web/wp-content/uploads/2014/09/pro_redux_21.jpg

These are going to be the locking pins:
http://gtwr.de/web/wp-content/uploads/2014/09/pro_redux_23.jpg

I made a template for the cam section on the locking pin in scale 20:1:
http://gtwr.de/web/wp-content/uploads/2014/09/pro_redux_25.jpg

Here I machined the cam section with a 0.5mm endmill on the pantograph machine:
http://gtwr.de/web/wp-content/uploads/2014/09/pro_redux_28.jpg

The allmost finished locking pins, I need to get a 0.3mm slitting saw to cut the screwdriver slot:
http://gtwr.de/web/wp-content/uploads/2014/10/pro_redux_32.jpg

There I tried my hand on the grip bushings – M2 external thread, M1,2 internal:
http://gtwr.de/web/wp-content/uploads/2014/10/pro_redux_47.jpg

Turing of the spring guide:
http://gtwr.de/web/wp-content/uploads/2014/10/pro_redux_68.jpg

After turning the backside and drilling:
http://gtwr.de/web/wp-content/uploads/2014/10/pro_redux_71.jpg

And the finished spring guides:
http://gtwr.de/web/wp-content/uploads/2014/10/pro_redux_78.jpg

I also finished the spring bushings, with the lug that is punched to the inside and the serrations on the face:
http://gtwr.de/web/wp-content/uploads/2014/10/pro_redux_90.jpg

I cut one open so the lug thats bent to the inside can be seen:
http://gtwr.de/web/wp-content/uploads/2014/10/pro_redux_84.jpg

I did this with a small rectangular punch and an die that went on the inside of the bushing.

Here I started working on the receiver. I got the stock already machined to size and thickness:
http://gtwr.de/web/wp-content/uploads/2014/10/pro_redux_98.jpg

For upcomming operations I already drilled the hole for the slide stop, where most measurements are taken from:
http://gtwr.de/web/wp-content/uploads/2014/10/pro_redux_105.jpg

I cut the area where the main spring will sit with the part standing in the vice:
http://gtwr.de/web/wp-content/uploads/2014/11/pro_redux_115.jpg

And the clearance slot for the barrel link:
http://gtwr.de/web/wp-content/uploads/2014/11/pro_redux_121.jpg

Going for the barrel links – I did those also on the pantograph machine:
http://gtwr.de/web/wp-content/uploads/2014/10/pro_redux_110.jpg
http://gtwr.de/web/wp-content/uploads/2014/10/pro_redux_111.jpg

After the milling operations where done they just needed to be parted off:
http://gtwr.de/web/wp-content/uploads/2014/10/pro_redux_112.jpg

The finished barrel links:
http://gtwr.de/web/wp-content/uploads/2014/10/pro_redux_114.jpg

There is also a video on the making of the barrel link:
http://youtu.be/kV2tkT_0xdk

The barrel links fit already:
http://gtwr.de/web/wp-content/uploads/2014/11/pro_redux_124.jpg

Last part I made so far is the barrel bushing. I started with turned parts:
http://gtwr.de/web/wp-content/uploads/2014/11/pro_redux_128.jpg

I machined the templates for the pantograph on the cnc out of 5mm polycarbonate:
http://gtwr.de/web/wp-content/uploads/2014/11/pro_redux_131.jpg

(Why I do this on the pantograph, not on the cnc? Because the pantograph machine reaches way higher rpm than my cnc which tops out at 6000Rpm. And the pantograph is more fun to run :) )

The template clamped on the machine – The center hole is used to hold the stylus in place while I center the part with a DTI:
http://gtwr.de/web/wp-content/uploads/2014/11/pro_redux_132.jpg

The finished parts:
http://gtwr.de/web/wp-content/uploads/2014/11/pro_redux_136.jpg

For the barrel bushing there is also a video:
http://youtu.be/VcNmf5njlp0

More will follow :)

Stefan

Willy
11-02-2014, 05:37 PM
Stefan thanks for posting this here as it will receive more views here. Although I have not seen all of your links yet I must comment on what I have seen already. Beautiful work and craftsmanship! I also like the very well documented steps of this project. The videos and photos are excellent.
Thank you!

loose nut
11-02-2014, 06:29 PM
If it's is any help I have a set of plans for the 1911 (I don't know for sure if it is the 1911 or 1911A1 or what the difference is). I can e-mail them to you if it would help. Just scale them down.

loose nut
11-02-2014, 06:30 PM
Just double checked and they are the 1911A1.

boslab
11-02-2014, 07:25 PM
Nice work, can miniture ammo be made?, a 1911 for mini me!
Like the pantograph myself, I have an old Taylor Hobson no3, it's a versatile little machine, I liked the roller stylus, I never thought of that, but I'm self taught with them, a roller will be made for the next job, what cutters do you use?, looked solid carbide
Mark

stefang
11-03-2014, 04:52 PM
Hi and thank you for the comments, I appreciate those very much :)


If it's is any help I have a set of plans for the 1911 (I don't know for sure if it is the 1911 or 1911A1 or what the difference is).

Thank you, but the set of drawings from Mr. Benson ( http://m1911a1redux.com/ ) is complete and of very high quality.


I liked the roller stylus, I never thought of that, but I'm self taught with them, a roller will be made for the next job, what cutters do you use?, looked solid carbide

The roller was unintentionally, I needed a stylus with 20mm diameter - So I put just a free running disc with a reamed 6mm hole over my straight 6mm stylus and it worked fine :)
I still have to make a whole set of rollers (also over and undersized for roughing/finishing)....

I use allmost exclusely carbide endmills - This was a 2mm coated four flute with long shank, I think made by Mitsubishi.

Today I started on the rear sight – The drawing (converted to metric and scaled down by one third) and the raw material, carbon steel 6x6mm square:
http://gtwr.de/web/wp-content/uploads/2014/11/pro_redux_138.jpg

I chucked the material up in this prism like thing and machined the outer contour:
http://gtwr.de/web/wp-content/uploads/2014/11/pro_redux_139.jpg
http://gtwr.de/web/wp-content/uploads/2014/11/pro_redux_144.jpg

For the step with the radius on the bottom I ground a single lip cutter with an 0.8mm cornerradius:
http://gtwr.de/web/wp-content/uploads/2014/11/pro_redux_145.jpg

The center section is only 0.51mm wide on the top – The single lip cutter runs very well at high rpm and feed with low depth of cut:
http://gtwr.de/web/wp-content/uploads/2014/11/pro_redux_147.jpg
http://gtwr.de/web/wp-content/uploads/2014/11/pro_redux_148.jpg

The small cutout in the center was done with a 1mm endmill:
http://gtwr.de/web/wp-content/uploads/2014/11/pro_redux_149.jpg

Stefan

mars-red
11-03-2014, 05:01 PM
This is my kind of project- great work!

stefang
11-16-2014, 03:49 PM
Thank you Max, I enjoy your work too :)

I could get a few ours in my shop to continue on the M1911.

The finished rear sight, ready to be cut of its stem:
http://gtwr.de/web/wp-content/uploads/2014/11/pro_redux_153.jpg

Cutting of the sight with an 0.6mm thick slitting saw:
http://gtwr.de/web/wp-content/uploads/2014/11/pro_redux_157.jpg

The finished rear sights:
http://gtwr.de/web/wp-content/uploads/2014/11/pro_redux_159.jpg

There is also a video on the making of the rear sights:
http://youtu.be/02p1ff7bfHg

Continuing the work on the slide, machining the underside:
http://gtwr.de/web/wp-content/uploads/2014/11/pro_redux_161.jpg
http://gtwr.de/web/wp-content/uploads/2014/11/pro_redux_162.jpg

Milling out the ejector slot:
http://gtwr.de/web/wp-content/uploads/2014/11/pro_redux_165.jpg

Finishing the ejector slot from the other side:
http://gtwr.de/web/wp-content/uploads/2014/11/pro_redux_168.jpg

I love using the pencil CAM for programming ;)
http://gtwr.de/web/wp-content/uploads/2014/11/pro_redux_167.jpg

Current status on the slides:
http://gtwr.de/web/wp-content/uploads/2014/11/pro_redux_169.jpg

Stefan

iMisspell
11-16-2014, 05:53 PM
I find this kind of work so interesting.
Really nice work, thanks for sharing.

Looking at your site, is there a built in English translation ?
http://gtwr.de/web/

_

stefang
11-24-2014, 03:27 AM
:)


Looking at your site, is there a built in English translation ?

Unfortunately not yet, but I have that on my to-do list, at least to translate the site step by step.

I did some more work on the slides. Here I roughed out the guideways on the bottom of the slide:
http://gtwr.de/web/wp-content/uploads/2014/10/pro_redux_170.jpg
http://gtwr.de/web/wp-content/uploads/2014/10/pro_redux_171.jpg

Testing the with of the slot with a set of gauge blocks:
http://gtwr.de/web/wp-content/uploads/2014/10/pro_redux_172.jpg

Setting the slide up in the v-Block to predrill the bores for the barrel and the spring guide:
http://gtwr.de/web/wp-content/uploads/2014/10/pro_redux_173.jpg
http://gtwr.de/web/wp-content/uploads/2014/10/pro_redux_174.jpg

Boring the spring guide hole to size using a very small carbide boring bar in the Wohlhaupter UPA1 head:
http://gtwr.de/web/wp-content/uploads/2014/10/pro_redux_176.jpg
http://gtwr.de/web/wp-content/uploads/2014/10/pro_redux_175.jpg

Spring guide fits into the bore:
http://gtwr.de/web/wp-content/uploads/2014/10/pro_redux_178.jpg
http://gtwr.de/web/wp-content/uploads/2014/10/pro_redux_177.jpg

Current status:
http://gtwr.de/web/wp-content/uploads/2014/10/pro_redux_179.jpg

And there is also a video of the machining operations:

http://youtu.be/ezjeowK9YWA

Stefan

Euph0ny
11-24-2014, 05:05 AM
Fantastic work, Stefan. Thanks.

I really like your clever workholding ring with the three screws and the improved-model Tubalcain no-spill oil cup - putting the tube through a pop-off lid is a clever touch!

Mike Hunter
11-24-2014, 07:22 AM
Awesome !!!

gbritnell
11-24-2014, 01:12 PM
Stefan,
Outstanding work. I really enjoy following your progress. I too like your work holding ring. Is that something that you purchased or just made up?
gbritnell

daveo
11-24-2014, 02:51 PM
Tuned in! Thats a very cool project!!!

stefang
12-02-2014, 04:13 PM
Thank you guys, I very much appreciate your comments :)


I too like your work holding ring. Is that something that you purchased or just made up?
I bought it used from a machinery dealer, I think its normaly used to machine electrodes for Ram EDM. We have some at work that look almost the same, so I think its a commercial available tool.

Got some more progress:

I ground this extra long boring bar to bore out the barrel clearance hole:
http://gtwr.de/web/wp-content/uploads/2014/12/pro_redux_183.jpg

I also turned myself a go/nogo gage pin with 5,92mm and 5,94mm diameter to check the hole:
http://gtwr.de/web/wp-content/uploads/2014/12/pro_redux_184.jpg

The boring operation went very well, the boring bar didnt chatter and I got a cylindrical hole:
http://gtwr.de/web/wp-content/uploads/2014/12/pro_redux_186.jpg

For the moment I dediced to pause on the slide because I have to make some decisions on how to proceed, so I went on making the sear.
Drawing, stock material and the 10:1 template for the pantograph:
http://gtwr.de/web/wp-content/uploads/2014/12/pro_redux_187.jpg

The template setup on the machine, the stylus sits in the center hole (In that position the workpiece gets centered under the spindle and also drilled), in the foreground there are two rollers for the stylus, one with 21mm diameter for roughing (on a 10:1 ratio with a 2mm endmill that will leave 0,05mm allowance for finishing) and one with 20mm for finishing:
http://gtwr.de/web/wp-content/uploads/2014/12/pro_redux_193.jpg

Centering the stock material by swinging an arc with the DTI:
http://gtwr.de/web/wp-content/uploads/2014/12/pro_redux_188.jpg
Roughed out the profile with an 2mm carbide endmill taking two cuts of 1,5mm depth, finished it with an new 2mm threeflute endmill cutting at full depth. The hole was drilled with an 0,9mm carbide drill – I prefer the stubby carbide drills as they drill a very tight and precise hole:
http://gtwr.de/web/wp-content/uploads/2014/12/pro_redux_189.jpg

The machined profile of the sears:
http://gtwr.de/web/wp-content/uploads/2014/12/pro_redux_192.jpg

I am going to cut the slot with a tiny 10mm slitting saw on a arbor:
http://gtwr.de/web/wp-content/uploads/2014/12/pro_redux_194.jpg
http://gtwr.de/web/wp-content/uploads/2014/12/pro_redux_195.jpg

Almost finished, two corners need to be chamfered and one radius needs to be picket out to a sharp corner. Last stepp will be parting off:
http://gtwr.de/web/wp-content/uploads/2014/12/pro_redux_196.jpg

Stefan

dewat
12-02-2014, 05:29 PM
Outstanding !!!!! Mehr bitte. :D

.

stefang
12-03-2014, 10:48 PM
Outstanding !!!!! Mehr bitte. :D

Bitteschön, there you go:


http://youtu.be/6apx6a4Ytvg

:)

Stefan

stefang
12-06-2014, 05:01 AM
Next thing that was made were the hammer struts:
http://gtwr.de/web/wp-content/uploads/2014/12/pro_redux_206.jpg

I started with a template sawed out of 2mm DiBond material:
http://gtwr.de/web/wp-content/uploads/2014/12/pro_redux_202.jpg

Then I glued a piece of spring steel to a sacrificial piece of brass:
http://gtwr.de/web/wp-content/uploads/2014/12/pro_redux_203.jpg

The hole was drilled with an 0,8mm ball endmill, the profile was milled with an 1mm straight endmill in a few passes:
http://gtwr.de/web/wp-content/uploads/2014/12/pro_redux_204.jpg

Last step in machining was to stand the part up and round the end – I uses a 2mm ball endmill to get a nice transfer between the round and square section:
http://gtwr.de/web/wp-content/uploads/2014/12/pro_redux_205.jpg

Again, theres a video of the process:

http://youtu.be/ZBfuseY7RIc

And finaly an assortment of parts that have been finished (or partialy finished in case of the slide) until now:
http://gtwr.de/web/wp-content/uploads/2014/12/pro_redux_207.jpg

Stefan

dewat
12-06-2014, 12:32 PM
It's a pleasure to see this project progress. Thanks

.

stefang
01-06-2015, 07:25 AM
Because of the chuck jaws I made recently, I took a break on the M1911, but now I am back on it again and I made the mainspring housing.

I did the most machining with the part hanging on the round stock:
http://gtwr.de/web/wp-content/uploads/2014/10/pro_redux_230.jpg

Parting off on the lathe, using a inserted parting tool:
http://gtwr.de/web/wp-content/uploads/2014/10/pro_redux_233.jpg

Then I made this little alignment jig to hold it in the vice, so I could machine the splines on the side of the housing:
http://gtwr.de/web/wp-content/uploads/2014/10/pro_redux_236.jpg
http://gtwr.de/web/wp-content/uploads/2014/10/pro_redux_238.jpg

The bottom surface got two holes and a cutout machined:
http://gtwr.de/web/wp-content/uploads/2014/12/pro_redux_251.jpg

Then I profiled the backside of the housing on the cnc, I have no photo of that, only a screenshot out of CamBam:
http://gtwr.de/web/wp-content/uploads/2014/12/pro_redux_251_2.jpg

And now for the tricky part, there had 9 groves to be cut on the concave surface using a small single lip cutter. I wanted to do that on the engraving machine as its capable of very high rpm and it can engrave on concave/convec surfaces when you use the patternholder and a negative pattern of the part:
http://gtwr.de/web/wp-content/uploads/2014/12/pro_redux_253.jpg

The patternholder gets mounted to the machine and the spindle gets set to free float - The tip on top of the spindle bears against the negative template and follows it:
http://gtwr.de/web/wp-content/uploads/2014/12/pro_redux_254.jpg
http://gtwr.de/web/wp-content/uploads/2014/12/pro_redux_255.jpg

And with that setup I was able to engrave the groves:
http://gtwr.de/web/wp-content/uploads/2014/12/pro_redux_257.jpg

The last step where the facets on top of the splines, I simply cut them with a 60° single lip cutter:
http://gtwr.de/web/wp-content/uploads/2015/01/pro_redux_260.jpg

And here are the finished spring housings:
http://gtwr.de/web/wp-content/uploads/2015/01/pro_redux_261.jpg


http://youtu.be/nc8MNdzkzBM

Stefan

dewat
01-06-2015, 03:11 PM
Still amazing !!!

Thanks
.

Catshooter
01-11-2015, 03:13 AM
That is a very cool project and you're doing excellent work.

Making three actually, aren't you?


Cat

stefang
02-08-2015, 06:33 AM
Making three actually, aren't you?

I try to make two, therefore I make at least four of every part, to give me some more parts to waste...

I decided to continue with the magazines. The most complicated part on those is the magazine tube itself which is made from 0.25mm sheetmetal and needs to be welded. I did a testweld on some single edge razor blades that was not to good, but I was sure to get it somehow done:
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_262.jpg

That out of the way I proceeded to machine a bending punch/die. Here I am milling down a piece of drillrod that will become the punch – Carbide roughing endmill
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_264.jpg
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_265.jpg

Machining the radius on top with an 2mm ball endmill:
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_268.jpg

Making the actual die:
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_272.jpg
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_273.jpg

The die with the stop blocks that hold the piece of sheetmetal in center:
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_274.jpg

Adjusting the stops with gauge blocks:
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_275.jpg

Cutting a piece of 0.25mm sheetmetal to size – To prevent warping with shears I just score it pretty deep with a knive and break it:
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_287.jpg

Test, using the drillpress as a press, works like a charm, but the forces involved lead me to use the benchvice in future for that job:
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_288.jpg

Cutting down the overhanging sheetmetal:
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_299.jpg

Bending the material over:
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_301.jpg

To make the welding process a bit more controlled and take my shaking hand out, I rigged my tig torch up with a laboratory stand:
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_310.jpg

With that setup my tungsten has always the same distance to the part and I can easy follow a straight line as I can run my die, along the fence on my sub-welding table:
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_311.jpg

The weld came out pretty ok – I didnt run a continous arc, just spotweld after spotweld:
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_313.jpg
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_314.jpg

After cleanup the magazine tube, still with the bendingpunch in it can be levered out of the die:
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_306.jpg
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_307.jpg

They came out very well:
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_308.jpg
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_309.jpg

Five good ones, five for the trashbin (Or to be used as setup parts:
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_315.jpg

Also there is again a video on the bending/welding process:

http://youtu.be/bV-TgIx6vMk

Stefan

adatesman
02-08-2015, 08:54 AM
Wow. Just.... Wow. :)

dewat
02-08-2015, 01:41 PM
Wow. Just.... Wow. :)

+1 ....

stefang
02-15-2015, 07:35 PM
Thank you guys!

I went on to do the actual machining on the magazine tubes. First I made up an aluminum filler piece that fits into the tubes so I can clamp them in the vice:
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_316.jpg

Then I had to tilt my vice by 9deg using my shopmade scissortype sine bar:
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_318.jpg

I cut the bottom of the magazin tubes on the set angle and also machined the step on the front of the radius:
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_319.jpg
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_320.jpg

Drilling the holes in the side of the magazine:
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_322.jpg

Then I machined the contour of the magazine lips on the bending piece I used before:
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_327.jpg

Then it was just a matter of hammering the magazine lips over the bending piece:
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_331.jpg

After the bending, a 2mm endmill was ran trough to clean up everything:
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_333.jpg
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_332.jpg
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_334.jpg

To cut the complex shape on front of the magazines I made two templates for the pantograph machine:
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_335.jpg

With the first one I cut a full radius over the complete height:
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_338.jpg

After changing the templates I cut the step to half the depth:
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_339.jpg

http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_340.jpg

There was some cleaning with needle files to be done, the left one is right of the machine, the right one is cleaned up:
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_341.jpg

http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_342.jpg
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_343.jpg

And with a fake bullet:
http://gtwr.de/web/wp-content/uploads/2015/02/pro_redux_346.jpg


http://youtu.be/dHFJDRY9-WI

And after finishing the video i realised that I forgott to cut the slot for the magazine catch...will do that later :D

Stefan

dewat
02-16-2015, 12:48 PM
Still amazed, thanks for taking the time to share.

.

boslab
02-16-2015, 06:38 PM
Will this thing actually fire?, I suspect so, not knowing diddly squat about guns and ammo that is, don't see a lot of guns in the UK, thank goodness, with all the nutters running around it would be carnage.
Nice job btw
Mark

Walter
02-17-2015, 05:45 PM
Great work. I've been interested in doing something like this forever, I'm an absolute 1911 but myself. :-)

Its not my fault, I didn't do it, I wasn't even there, and I wouldn't admit to it anyways.