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  #41  
Old 12-12-2012, 1:33 PM
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Place the allignment plate onto of the playdough. Close the top cover and it will compress the playdough but keep it close to the top cover.
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  #42  
Old 12-12-2012, 1:34 PM
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Once the top cover is closed I used a clamp appling pressure to the allignment plate to keep it in place when I open the top cover back up
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  #43  
Old 12-12-2012, 1:35 PM
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When you open the top cover back up the alignment plate will be in place and you can scribe its location for machining.
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  #44  
Old 12-12-2012, 1:36 PM
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Here you can see the scribe mark, you can also see where I should have place a piece of glad wrap to cover the lock, now I have to pick playdough out of it.
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  #45  
Old 12-12-2012, 1:38 PM
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Now we can start to machine the slot for the denial plate. Lonies directions call for a .60" deep .125" wide cut exact location determined by the fitting plate. Here is where we hope everything lined up right durring the fitting.
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  #46  
Old 12-12-2012, 1:39 PM
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Here is the slot cut. I still have to adjust the front denial island.
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  #47  
Old 12-13-2012, 11:37 AM
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Now we can add the .60" to the allignment plate measurements on each side and trim the rest off the denial plate.
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  #48  
Old 12-13-2012, 11:39 AM
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here you can see how the denial plate slides into the slots we machined in the side plates.
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  #49  
Old 12-13-2012, 11:42 AM
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If everything was done correct the denial plate will be centered in the box and the top cover will close no problem
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  #50  
Old 12-13-2012, 12:03 PM
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You will also need to machine a small notch so that the front cover can close with the trip installed
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  #51  
Old 12-13-2012, 12:05 PM
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Now we rivet the cam in place. I like to use counter sunk rivets and counter sink the holes so I can finich them flush.
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  #52  
Old 12-13-2012, 12:06 PM
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Here you can see I started to set the rivets. I will also rivet the check lever on at this time too.
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  #53  
Old 12-13-2012, 12:06 PM
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Here is the inside of the plate with the cam riveted and cleaned up. You can also see that I reshaped the front denial island so that the extractor would be able to clear it and move upwards.
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  #54  
Old 12-13-2012, 12:07 PM
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Other side after cleaning up the cam rivets
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  #55  
Old 12-13-2012, 12:09 PM
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After settiing the check lever rivets and cleaning up the inside. Only rivet the top top holes. The bottom two will be riveted when we get to the bottom plate
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  #56  
Old 12-13-2012, 12:11 PM
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Next we remove the trigger bar and mark how much we have to take off so it will fit over the trip
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  #57  
Old 12-13-2012, 12:12 PM
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The best way to cut this is with a dremel and cut off wheels then file.
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  #58  
Old 12-13-2012, 12:13 PM
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The top cover should close without hanging up on the trip.
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  #59  
Old 12-13-2012, 7:04 PM
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Assemly with pop rivets one last time to check to make sure everything is working right and that nothing hangs up. I also check the fire control group by firing a primed cartridge. I made a short video, you will get the idea.
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  #60  
Old 12-13-2012, 7:06 PM
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I guess my video did not work. lets try it this way instead

http://s1342.beta.photobucket.com/us...60cca.mp4.html
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  #61  
Old 12-13-2012, 7:10 PM
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I made my own rivet tool based off other rivets I found on the top cover. I am using a 1919 bucking bar which worked great for the box where the base plate mounts but noe so great for the rivets on the trunion.
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  #62  
Old 12-13-2012, 8:38 PM
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Here we are playing with different heights to get the right looking rivet head.
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  #63  
Old 12-13-2012, 8:41 PM
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There is definitely a maxim in my furture and would love to find a 1917a1 kit
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  #64  
Old 12-13-2012, 8:43 PM
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one side done
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  #65  
Old 12-13-2012, 8:53 PM
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And on to the other side. Here is where you will rivet in the travel stop for the tripod. I use longer rivets and counter sink the outside to finish them flush.
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  #66  
Old 12-14-2012, 2:07 AM
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This may be a stupid question, but how are you expanding those rivets? Are you hitting them with a hammer and that blunt punch I see in the pictures? What are the rivets made of?
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  #67  
Old 12-14-2012, 10:20 AM
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For the rivets I finish flush I use a ball peen hammer to spread and fill the counter sink then flatten it with the other side. The rivets that are raised and rounded I use a tool the I made. Using a punch as a doner I cut off the head then using a 1/8 ball endmill turned a divet which will form the top of the rivet.
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  #68  
Old 12-14-2012, 4:05 PM
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Now that the box is riveted up we can move on to joining the box to the trunion. To do that we must first solder the box and trunnion together. This will close up some holes we are not using the seal up the water jacket area. First we clean and rough up the area that we will be soldering.
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  #69  
Old 12-14-2012, 4:09 PM
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Then spread the solder paste in the areas that need to be joined or sealed up.
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  #70  
Old 12-14-2012, 4:10 PM
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And on the trunion too
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  #71  
Old 12-14-2012, 4:11 PM
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I use two 1/8 rods and the front cover locking pin to get the box and trunion alligned right
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  #72  
Old 12-14-2012, 4:12 PM
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I then clamp it all together
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  #73  
Old 12-14-2012, 4:14 PM
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And apply heat to the area wear I spread the solder paste.
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  #74  
Old 12-14-2012, 4:15 PM
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When the solder bubbles in the holes you know you are done.
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  #75  
Old 12-14-2012, 4:21 PM
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Next I thread the holes that can not be set with rivets. There are a total of 8 holes. At this point I put standard screws in them but do not lock tight them in. I am using them to help hold the gun together while I finish up with the rivets. Later I will replace them with different screws and lock tight them in.
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  #76  
Old 12-14-2012, 4:24 PM
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Back to riveting. A couple of the rivets were a bit long and the head did not form as nice as the others. Not to worry you can reshape that head later with a needle file and some patience.
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  #77  
Old 12-14-2012, 4:25 PM
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and the other side.
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  #78  
Old 12-14-2012, 4:30 PM
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once all the bottom trunion rivets are set we have a couple of special rivets to get in. Remember how I made a quick fusee cover rivet to use for testing? Now we have to make another one but with a longer shank to go all the way through the side plate and trunion.
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  #79  
Old 12-14-2012, 4:32 PM
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Heres how it looks after im done.
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  #80  
Old 12-14-2012, 4:34 PM
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it gets poked all the way through and gets riveted in this little pocket.
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