A Guide to the Drilling, Reaming, and

Broaching a Bolt Action Receiver at Home

By Raymond Benwood

A Guide to the Drilling, Reaming, and

Broaching a Bolt Action Receiver at Home
By Raymond Benwood

Copyright 2006 Raymond Benwood

Due to the attacks on our second amendment I have decided to release this book to
the general public for information and educational purposes, with one reserve.
I the author of this book do hereby release this book into the public domain to be
reproduced and distributed in all forms for Informational and Educational
purposes.
It is my personal desire that this work be printed, reprinted, stored, copied, and
distributed on both paper and electronic media, such as CDs, DVDs, and e-mails
by any group, organization and/or individual for the purpose of supporting,
encouraging and promoting a second amendment culture in the United States of
America.
Neither the author nor his family assumes any responsibility for the use or misuse
of information contained in this book.
Any mention made in this book pertaining to any group, organization, business or
trademark by the author is either opinion or for reference purposes only and does
not constitute an endorsement by either party
I encourage the distribution of this intellectual property, with one reserve, as stated
above.
This works may NOT be used by any group, organization, and/or individual for
any anti-second amendment purposes.

Table of
______________________

Contents
Introduction1
Chapter 1:

Tools and Equipment.3

Chapter 2:

The Strength is in the Steel9

Chapter 3:

Receiver Design12

Chapter 4:

Grinding the Broaches. 20

Chapter 5:

Starting the Receiver.26

Chapter 6:

Broaching the Receiver.. 31

Chapter 7:

Let the Milling Begin. 37

Chapter 8:

Milling the Magazine Well/ Bolt Stop Flange.. 56

Chapter 9:

Milling the Receiver to Profile .71

Chapter 10:

Final Shaping of the Receiver...76

Chapter 11:

Odds and Ends and Finishing Touches 82

Chapter 12:

Final Thoughts. 92

Warning
At the time of the writing of this Book it was legal to make a
firearm for personal use, provided the individual is not
prohibited from doing so by Federal, State, or Local laws.
Some States may have a prohibition on certain features or types
of firearms a person may own.
It is up to the builder of any type of Personal Use Firearm to
know and follow such law as may apply to them in the
Jurisdiction in which they live. If in doubt, I encourage you to
seek legal advice.
The Information presented here represents the knowledge and
abilities of one man. Therefore, be advised that neither the
author nor his family assumes any responsibility for the use or
misuse of information contained in this book.
This book contains information that requires skills and
knowledge of machine tools and their usage that would be of
danger to an untrained or unskilled person. Therefore the
information contained in this book is for information and
education purposes only.
The author of this book is not a lawyer, therefore any references
made by the author too any law does not represent legal advice.

For the sake of clearing up confusion on the home building of a Personal use
Firearm, I have included a page from the web site of the BATFE along with their
web address. As stated earlier at the time of the writing of this book building a
Personal Use Firearm is legal. (Web page was saved early in 2006)
http://www.atf.treas.gov/firearms/faq/faq2.htm#a7

(A6) Does the GCA control the sale of firearms parts? [Back]
No, except that frames or receivers of firearms are "firearms" as defined in the law and
subject to the same controls as complete firearms. Silencer parts are also firearms under
the GCA, as well as under the National Firearms Act (NFA). Certain machinegun parts,
such as conversion parts or kits, are also subject to the NFA.
The GCA generally prohibits the transfer and possession of large capacity ammunition
feeding devices manufactured after September 13, 1994. "Large capacity ammunition
feeding devices" are those that can accept more than 10 rounds of ammunition. [18 U. S.
C. 921( a)( 3), (24), and (31), 922( w), 27 CFR 178.11 and 178.40a]

(A7) Does the GCA prohibit anyone from making a handgun, shotgun or rifle?
[Back]
With certain exceptions a firearm may be made by a nonlicensee provided it is not for
sale and the maker is not prohibited from possessing firearms.
However, a person is prohibited from making a semiautomatic assault weapon or
assembling a nonsporting semiautomatic rifle or nonsporting shotgun from
imported parts. In addition, the making of an NFA firearm requires a tax payment and
approval by ATF. An application to make a machinegun will not be
approved unless documentation is submitted showing that the firearm is being made for a
federal or state agency. [18 U. S. C. 922( o), (r), (v), and 923, 27 CFR 178.39, 178.40,
178.41 and 179.105]

(B5) Are there certain persons who cannot legally receive or possess firearms and/or
ammunition? [Back]
Yes, a person who
(1) Has been convicted in any court of, a crime punishable by imprisonment for a term
exceeding 1 year;
(2) Is a fugitive from justice;
(3) Is an unlawful user of or addicted to any controlled substance;

(4) Has been adjudicated as a mental defective or has been committed to a mental
institution;
(5) Is an alien illegally or unlawfully in the United states or an alien admitted to the
United states under a nonimmigrant visa;
(6) Has been discharged from the Armed Forces under dishonorable conditions;
(7) Having been a citizen of the United states, has renounced his or her 8 citizenship;
(8) Is subject to a court order that restrains the person from harassing, stalking, or
threatening an intimate partner or child of such intimate partner; or
(9) Has been convicted of a misdemeanor crime of domestic violence cannot lawfully
receive, possess, ship, or transport a firearm. A person who is under indictment or
information for a crime punishable by imprisonment for a term exceeding 1 year cannot
lawfully receive a firearm. Such person may continue to lawfully possess firearms
obtained prior to the indictment or information. [18 U. S. C. 922( g) and (n), 27 CFR
178.32( a) and (b)]

____________________________

Introduction
What started out as an
unpleasant trip to the funeral
home in the early 1990s has
turned into an obsession.
It all started when family
members began to reminisce
about a family member that
had worked as a cowboy in a
western Rodeo show in the
early 1900s.
Like many family members
listening to the tales of long
lost relatives, I tried to pay
attention to every detail.
This receiver was built with the tools and techniques discussed in this book

After I got home I had the opportunity to talk to my father about his grandfather
and the gun work that he had done. Perhaps the most fascinating part of the
conversation came when my father began to describe some of the gun work that
had been done by his grandfather. Drilling gun barrels by hand with bits that were
homemade, making gun parts that were first scribed onto a piece of steel, then cut
out with a hacksaw and then shaped with a file.
Then the conversation exposed the revelation that has lead to this book and my
interest in home gun building. My father began to describe some of the tools that
he remembered his grandfather had made and used some 60 years before, single
and multiple point cutters that were used to cut groves in guns. To this day I dont
think my father realized what those tools really were, they were broaches. My
father had described to me the broaching of a bolt action receiver and the making
of a gun barrel by his grandfather without realizing it. It must be noted that my
father was just a child at the time and did not understand what he was seeing.
1

Today we gun owners are lucky, we have modern firearms made from modern
steels. Parts made by computer controlled machines, manufacturing large
quantities of high quality interchangeable parts.
Lucky, well yes we have the benefit of modern steels and the quality of modern
manufacturing, but my father, grandfather and great grandfather could buy guns
through the mail, No background checks, No forms to fill out, nothing. To my way
of thinking that is Freedom, something that we as a nation and people have lost.
In my opinion ever since the passage of the 1968 Gun Control Act, gun ownership
in this country has come with permission slip. Homebuilding is not a way to
bypass the law but does allow an individual some limited protection against future
confiscation by building their own personal use firearm. Under the current law a
person may build a firearm for personal use, but that firearm may NOT be sold nor
can a firearm be built for another person other than the builder. The said firearm
may be transferred upon the death of the builder, but again not sold. There maybe
more to the current law, but that is my understanding.
After September 11th, 2001 I began to hear about builder squads, groups of people
that shared the cost of tooling and then built their own AR15s. The more that I
looked into homebuilding; I discovered web sites and a whole industry supplying
the home gunsmith and builder. I soon learned that many different types of
firearms were being made; AR15s, 1911s, AK47s, single shots, and even 50
calibers.
Now if you are building a semi-auto rifle, pistol or a shot gun there are some rules
that must be followed on the amount of imported parts that can be used. I wont
cover that here because we are not building a semi-auto or shot gun, therefore the
imported parts rule does not apply.
Now I am not a lawyer and I am not giving legal advice, but a rifle must have a
barrel that is rifled and is at least 16 inches long. I suggest you never use a barrel
less than 16.5 inches long. Its also my understanding that a rifle must be at least
26 inches in length overall. My suggestion is to make something close to a full size
rifle or carbine and not try to test the law. I prefer carbines or whats called a scout
rifle, theyre around 38-40 inches in length.

Chapter One
_______________________________________________

Tools and Equipment

The biggest challenge to homebuilding firearms for the novice, is the investment
in Machine Tooling and
other equipment that is
necessary to build
firearms. Naturally if you
wanted to build just one
firearm, the cost would be
prohibitive. However if
you are wanting to build
more than one firearm or
are wanting to repair,
maintain, or sporterize
firearms the cost factor
changes dramatically.
Lets say youre a person
that likes old guns and just
wants to make general
repairs or change barrels.
Above is a homemade action wrench used for Mauser and Springfield
bolt action receivers. Such a wrench is necessary when replacing or
installing a Barrel on a rifle. Its also the action wrench used for the bolt
action that is discussed in this book.

On some old bolt actions, this alone can justify the purchase of a lathe large
enough to handle barrel work. What about repairing old or obsolete firearms,
firearms old enough that parts are no longer available, this type of work can justify
the purchase of a Milling Machine.

Many homebuilders make the holding fixtures, barrel vises, and action wrenches
that they need to work on their firearms. They also porting gun barrels,
rethreading, installing choke tubes, making firing pins the list goes on and on.
One of the main objectives of this book is to encourage and strengthen a second
amendment culture in this country. I strongly encourage every reader to learn how
to maintain and repair your firearms, to the very best of your abilities. I realize that
the vast majority of people in this nation will never be capable of making their own
personal use firearm, so its up to those who can to keep homebuilding alive.
To determine what you need to buy first depends on what type of work you want to
do. Barrel work will require a lathe that is large enough to handle both the length
and diameter of the barrel. I know of many people that buy these little 7x10 or
7x12 lathes, but for legitimate barrel work there just too small. Another size of
lathe that is often bought are these little 9x20 lathes made in China or Taiwan,
again they are closer to the length that is needed but lack the slower speeds for
threading, they also come with very small chucks. Now do not confuse these little
imported lathes with lathes like the South Bend or other older USA made lathes. A
9x30 South Bend or Sheldon lathe has the slower speeds necessary for barrel work
and have a reputation of quality built over decades. However for building the
Mauser type receiver in this book, it will require a lathe that can handle at least an
8 inch 4 jaw independent chuck to accommodate the eccentric turning for the 3rd
locking lug for the Mauser design.
There are many sizes and brands of lathes in the market place, 12x36, 13x40 and
16x40 will be some of the sizes that you will run across in selecting a lathe. I
personally suggest you purchase a 13x40 lathe; this size is capable of handling a 10
inch, independent 4 jaw chuck. If you are a shopper of these wholesale and freight
discount tool suppliers, its possible to buy a 13x36 or 13x40 lathe for less than
$3000.00. Now if $3000.00 scares you, you can buy a 12x36 lathe for $2000.00
that can still handle a minimum 8 inch, 4 jaw chuck. Now there is the possibility
that someone makes a 10inch 4 jaw chucks for a 12 inch lathe it may cost extra,
but it may save you $700-800 bucks, so shop around.
What about used lathes? Used lathes are just that, used. If you could find a good
used USA made lathe that is not worn out and comes with good chucks and some
tooling like cutters or a taper attachment for half the price of a new lathe then buy
it.
4