Archive for May 2012
Gallery dart gun: Part 2
by B.B. Pelletier

David Lurch Primary New York City gallery gun.
You readers have been very patient waiting for the next installment on this report! For that, I thank you. This project is taking a long time because it isn’t on the front burner (it probably isn’t even on the stove!) and because this is the kind of project in which you must “make haste slowly.”
Last time, I described the gun (it’s a smoothbore, so it’s not a rifle) and told you some of the general, as well as some specific, history of this particular example. Today, I want to honor Mr. Duskwight, our Muscovite blog reader who’s actively building a recoilless spring-piston rifle of his own design! Duskwight became fascinated with the performance of the Whiscombe air rifle and decided he could build one. Many of us have said similar things, but in this case the conviction remained even after he sobered up; and he’s spent many long months and a LOT of money making his dream come true.
By watching what happened to him, we’ve learned just how difficult and risky it is to build something from scratch. You don’t just tackle the technical job with all its intricacies and challenges. You also take on the entire socio-economic profile of your society, enduring substandard work, business failures, technical incompetence and on and on.
What I’ll show you today has one additional complexity added to the story. The builders didn’t have access to modern machine tools! Most of what you are going to see was made with files and hand labor. The metal hardening was done using a forge and eyeball, carefully judging the state of the metal by its color. If anything had to be timed, they did it with a pocketwatch instead of a digital timer linked to a time standard.
And the design came from someone’s head! There probably were no drawings in the “factory,” which was really just a quiet workshop. If they required anything to go by, there were possibly pattern parts that journeymen makers copied. While it’s true that what you are going to see is very simplistic, don’t make the mistake of thinking that it’s simple to do! Each part has to fit, and each part has a specific job to do if the whole item is to work as intended.
Enough talk, let’s see what this baby looks like. The first thing I will show is the new crank that Dennis Quackenbush made for the rifle.
Like the gun itself, this crank looks deceptively simple. It’s just a gear and a handle to turn it. Yes, but that gear isn’t as simple as it appears. Dennis has made cranks like this before, so he thought this one would be straightforward. He asked me for the width of the hole the gear fits into, as well as the width of a second hole on the inside of the gun that serves as a bearing for the crank once it’s inserted. I gave him those two dimensions, and within a month he sent me a pinion gear with instructions to try to fit it to the rack gear inside the gun.
I did, and it was a no-go. Dennis thought it would simply be a case of cutting a new gear that had more teeth; in his experience, these gears had one of only two different numbers of teeth on the pinion gear. Unfortunately, that wasn’t it, either! We were stumped. He had to see the gun.
We met at this year’s LASSO shoot, and he got the chance to examine the gun. When he did, he discovered that the rack gear in my gun is different from any other he’s seen. Apparently, David Lurch, who made the gun, had a better idea. He filed the rack gear teeth on a bias; as the crank is turned, the handle is also pulled tight against the mechanism because of the angle of the meshing teeth. A straight-cut gear cannot mesh with teeth cut on a bias, even when the number of teeth are the same because they aren’t set at the correct angle.
This time, Dennis took the gun home with him so he could cut the new pinion gear to the corresponding angle. He delivered the new crank assembly at the Malvern airgun show, and as you can see, it fits perfectly. He intentionally did not harden the new pinion gear because he wanted it to be the sacrificial part on the gun. The gun’s rack gear is hardened. If anything fails in operation, it’ll be this gear, which can always be remade. But he didn’t stop there.

The crank Dennis made fits the gallery gun very well. It’s still shiny, but I will take care of that with a browned finish later.

The crank turns the pinion gear, which engages the rack gear attached to the piston, withdrawing it as the springs are compressed.
Dennis contacted collector Larry Hannusch, who was kind enough to disassemble one of his Primary New York City gallery dart guns and remove the double volute spring mechanism so Dennis could have a look at it. Larry had seen my gallery gun at the Malvern airgun show the year before and was quite taken by it — as most collectors are. It’s not that this is an especially beautiful example, or that it’s extremely rare. It’s just that each one of these guns was made by hand, so every one is a collection unto itself. Just as Duskwight will be forever proud of all the effort he puts into his new rifle, so we can appreciate all the labor and skill that went into making one of these dart guns in the 1860s.
Larry brought the spring mechanism from his gallery gun and Dennis took measurements. He plans on making a new double-volute mainspring assembly for my gun. This will be the first time he’s made one of these springs; and to my knowledge, it hasn’t been done in recent times. It’s very possible that someone has made one and just not written about it, of course; but as far as I know, this will be the first time a double-volute mainspring has been made and documented in modern times. The documentation is important. How are we going to know about these old dart guns if we can’t test them? And nobody seems to be writing about them, so I guess I’m going to be the first one.
Last year at Malvern, Larry Hannusch showed me how to disassemble my gun. It proved about as easy as disassembling a Garand, but I had shied away from trying because of the age of the airgun. I really thought the gun would be fragile. But after seeing how things go together and how robust the parts are, I have confidence that I can work on this gun just as easily as I would a modern spring rifle.
A gallery gun works just like any other spring-piston airgun. The piston is driven forward by springs, rapidly compressing air in front of it that pushes the dart out the barrel. The big difference in this Lurch gallery gun is that the piston is very large (over 1.5-inches in diameter), and the piston stroke is quite long (about three inches). Those volute springs I thought were so fragile are probably far more robust than coiled steel wire springs. Seeing them up close and examining their potential travel gave me a new appreciation for the ingenuity of these old gun makers.

This is a gallery gun piston with its two volute springs and a spring guide that you cannot see. Notice that this piston seal doesn’t look like mine, which you’ll soon see. Mine is a replacement that needs to be trimmed.

The rear spring has been removed, and you can now see the spring guide that sits between both springs. Notice the piston rod is the rack gear that the crank works with to cock the gun.

Here you see how a volute spring works. It’s a coiled steel bar that’s pulled into this cone shape before hardening. It’s incredibly strong, plus it has a huge length of travel before becoming fully compressed.

This is the piston assembly with springs and spring guide. The tiny notch seen on the side of the piston rod opposite the rack gear teeth is the sear notch, properly called the “bent” at the point in time this gun was made. That’s what the trigger holds onto!
Are you enjoying this so far? Well, there’s more to come. Now, I’ll disassemble my gallery gun and show you the parts we’ve been talking about.

The compression chamber simply unscrews from the action of the gun. There’s no fastener holding the two assemblies together other than the threads seen here. You can actually see the color-hardening of the piston rod that has the rack gear teeth, but I’ll show it closer.

The rear screw is removed from the triggerguard, which is then unscrewed from the action. The front of the hand-filed brass guard is a screw!

Two screws are removed, and the wooden butt is separated from the action. You can see the rear of the piston rod in this view.

In this view, you can see the entire piston rod. The sear notch is also visible, opposite the rack gear teeth. Each gear tooth was filed by hand. Notice how much excess leather hangs down from the piston head.

The piston rod was hardened to a medium blue, which is pretty hard! The excess leather on the seal really stands out.

Here you can see that the gear teeth were cut on a bias to pull the cocking crank tight into the gun when it’s wound.

The side of the brass triggerguard still shows the marks of the maker’s file that shaped the piece to fit the gun after it was cast.
Well, that’s what the inside of a 150-year-old handmade airgun looks like. Dennis is going to make a pair of volute springs for me, but in the meantime I may try to get the gun operational with a coiled steel spring. It won’t be ideal, but it may provide me with a platform for testing the darts that I’m going to have to make.
The caliber appears to be exactly .25, as a .256 bullet will stop after entering the breech. So, I may be able to find large .25-caliber pellets that fit, and there may even be a .25-caliber dart I can find.
The bore is pretty ugly from the neglect of more than a century, so that will be my next task. I don’t know when I will return to this airgun again, but you can rest assured that it’s in the queue.
I found my silver dime!
In other news, my silver dime has returned! It was hidden under a Post-It note on a desk I’d used temporarily when changing computers several weeks ago. So, you will be seeing silver soon.
Quackenbush .308: Part 4
by B.B. Pelletier

Quackenbush .308 big bore is an attractive airgun.
The last time we looked at this Quackenbush .308 big bore was when I discovered that my rifle really likes Mr. Hollowpoint’s 68-grain hollowpoint bullet. I also tested a 150-grain Loverin-design bullet that was just a bit too heavy for the gun. It didn’t want to stabilize and was tearing elongated holes in the target at 50 yards.
If you’ll recall, I was running low on air that day, so I could fill the rifle to only 3,000 psi. That gave a stunning group that was smaller than one inch at 50 yards with the 68-grain hollowpoint, but I wondered whether it would do any better if I filled the rifle to higher pressure. I also wondered if going just a trifle faster would have stabilized the 150-grain bullet. There were a lot of unanswered questions after the last test.
Today, I’ll address those questions. I had a full air tank and a reasonably good day at the range. Certainly for testing something as stable as a .308, the light breeze was no challenge.
Shooting the 68-grain hollowpoints
I decided to fill the rifle to 3,500 psi, to see what kind of velocity that might give. The 68-grain bullet averaged 1051 f.p.s, on that much air and left about 3,100 psi in the tank for the second shot. That’s a muzzle energy of 167.15 foot-pounds.
Shot two averaged 1,010 f.p.s. with the same 68-grain bullet and generated 154.07 foot-pounds of energy. You might think that’s close enough to the first velocity that the bullets will print in the same place. They might if this was a firearm — but it’s an air rifle, and we have to take the flexing of the horizontal air reservoir into account. As the pressure inside the air reservoir changes, the reservoir — which is a long tube — flexes a tiny bit. Since it’s connected to the barrel, this flexing can cause movement in the muzzle.
The first shots printed about two inches higher on the target than the second shots. I knew they would from past experience shooting other big bores, so this came as no surprise to me. I actually shot one group of first shots (after a 3,500 psi fill) at one target and a separate group of second shots at a second target.
After seeing where the shots landed relative to the aim point, it’s possible to use the mil-dot reticle in my scope to shoot both shots into the same group by using two different aim points. This is a technique I learned several years ago with my .458 Outlaw; and with it, I can put five bullets into one inch at 50 yards. I didn’t try that on this day, however, because I was too busy learning the gun.
Neither group obtained this day was as good as the group I shot last time on just 3,000 psi of air. The first group that was shot on 3,500 psi measured 2.72 inches between centers for five shots, though four of those shots landed in a group measuring 1.219 inches.

Four of the five bullets were close at 50 yards on 3,500 psi. Two landed in the same hole.
The group that was fired on 3,100 psi measured 1.953 inches between centers. That’s twice the size of the best group that was shot several weeks ago on 3,000 psi, so I think this bullet is going too fast for best results. It looks to me like this 68-grain hollowpoint wants no more than 3,000 psi as a max charge. That would put the velocity at around 970-980 f.p.s.

Lower starting pressure gave a tighter group. This one was made with 3,100 psi.
Did the 150-grain bullets stabilize?
Again, the 150-grain bullets failed to completely stabilize — even when driven to 825 f.p.s (on 3,600 psi air) and generating 226.75 foot-pounds of energy at the muzzle.

Both bullet holes show evidence of tipping. The bullet is not stabilized.
Clearly, this Loverin bullet is too long to stabilize at the velocity this rifle generates. What’s needed is a 120- to 130-grain bullet that’s short, which means it must have either a round or a flat nose.
Some observations
I’m seeing a relationship between soft pure lead bullets and better accuracy. Any hardening alloy seems to open up the group.
Ditto for lubricated bullets. So far, the best, most accurate bullets are those that are completely dry. I see now that I need to cast some more 130-grain bullets in lead that is as pure as I can make it, and shoot them absolutely dry. I’ve seen the performance of pure lead bullets on game, and they hold together far better than hard alloy bullets do. Lead hardened with antimony breaks apart in large chunks, while soft lead mashes up like a wad of bubble gum when it hits game.
I’ve always questioned using a .308 for game as large as a deer. I know hunters who are better shots than I am do it all the time and have great success, but for me the .308 is more of a coyote and bobcat round. I’ll leave the deer and wild hogs to the .458 and keep this .308 for smaller game. It probably has a useful range of 125 yards in my hands. For an air rifle, that’s pretty far!
New-old-stock TS-45 air rifles!: Part 2
by B.B. Pelletier

This TS-45 rifle is probably at least 30 years old, yet also brand new.
Let’s look at the velocity of my new-old-stock TS-45. It’s been many years since I tested a really old Chinese airgun, so this was a nostalgic test for me. The TS-45 surprised me by being smoother to cock and fire than I imagined. The stock bolts were loose; but once I tightened them, the rifle fired quite smoothly and without a lot of aftershocks. I think that’s mostly due to the low power rather than any special fitting of the powerplant parts. Randy Mitchell did lubricate the powerplant of this rifle, but an older Chinese spring-piston air rifle needs a lot more than a lube tune to straighten up.
Trigger
The non-adjustable trigger is single-stage and if you pull it slowly it releases consistently at around 5 lbs., 14 oz. You don’t want it any lighter because of the danger of this mechanism slipping off the sear while loading. As cumbersome as it is, I always put my arm in the path of the cocking lever while I’m loading, just in case the sear lets go.
Velocity testing
The first pellet I tried to test was the 7.9-grain Crosman Premier — the so-called Premier Lite. I say I tried to test the velocity, but it was all over the place. The first shot went 564 f.p.s. and stayed there for two more shots. Then shot No. 4 leaped up to 750 f.p.s. And the feel of the gun at firing was more harsh, which told me it was dieseling pretty heavily. No detonations (explosions) were heard, but I suspect we were running just shy of them.
The Premier pellet fit the bore tightly, which I take as a good sign for potential accuracy. They’ll certainly be among those pellets I use for accuracy testing.
The velocity remained in the 700s for a few shots, then slipped back through the 600s to the 500s again. By the time I had fired 16 shots, we were down to 523 f.p.s.; but I knew the velocity would drop even lower than that, so I switched to the next pellet.
Next up were RWS Hobbys. They started out at 558 f.p.s. and dropped to 523 f.p.s. by the tenth shot, but the average for the string was a healthy 552 f.p.s. I suspect that number is a bit high, but it’s close to the real velocity with this lightweight pellet. Accepting it as fact gives us an average muzzle energy of 4.74 foot-pounds.
Like the Premier, these Hobbys also fit the bore tightly. They will be tested for accuracy, as well.
One nice thing about Hobbys is that they force a lot of dieseling for some reason. Perhaps, it’s due to their lightness, but I often find they’ll burn off excess lubricant when a gun has just been tuned.
The next pellet I tried was the Air Arms Falcon dome. These pellets fit the bore loosely, and I don’t have a lot of hope for their accuracy potential. They averaged 512 f.p.s., which seemed close to the real velocity. The range went from 500 to 529, so the rifle is definitely becoming more stable. At the average velocity, they generated 4.25 foot-pounds of muzzle energy.
Back to the Premiers
The rifle seemed to have settled down by this time, so I tried chronographing the Crosman Premiers once more. This time they were very stable at an average 464 f.p.s. The range went from 462 to 466 f.p.s., so the rifle seems to have settled in — at least as much as it’s going to for now. A crude spring rifle like this always needs about a thousand shots through it to fully break in and start performing the way it was meant to, but I doubt the velocity will change by more than 20-30 f.p.s.
At this velocity, the rifle generates an average 3.78 foot-pounds of muzzle energy. While that seems low, remember that spring guns do favor lighter pellets, and this one will probably follow that trend very closely.
So, how do I like the TS-45 so far? Well, I see a lot of pellet rifles over the course of a year, and this one isn’t the best that I’ve seen. It isn’t even in the top half. But it also isn’t at the bottom of the list. I’ve tested guns with a lot more power that I liked less than this one. If it weren’t so dangerous, this might be a nice little plinker.
The accuracy test is next, and those results will be very telling.











