Phew! I finally took the plunge and cut the Hand Ejector 2 down to size! This was was done by bandsawing the barrel a fraction of an inch long, and using a belt grinder to take it down to size and radius the outer edge. A round-head bolt, chucked in a hand drill, along with some lapping compound, was used to then chamfer/crown the bore edge. We did use a mill to cut the locator pin holes, but this is probably an optional step. JB weld was then used to affix the sight, after a thorough degreasing.
For blueing the sight, I first wetsanded all the flats to 600 grit. After degreasing, i submerged the entire sight in Birchwood Casey for a few minutes to blacken. I rubbed the excess off with some paper towels, and then ran it through a ceramic vibratory tumbler for 5 minutes. Finally, i hit the edges with some light sandpaper for some additional distressing. This process left the sight looking a nicely worn dark grey, which blended well with my worn and pitted revolver.
Overall, I couldn’t be happier with the results! The gun is mechanically sound, but has just the right amount of finish wear to be similar to the movie. And it had been previously modified to fire 45acp, which both detracted from its collectible relevance and makes it more feasible to shoot. Just what I’d wanted. Can’t wait to get to the range and see how much the zero moved!
Thank you guys for helping this all come together!
Before doing the HE2, I also cut and installed a sight on a sloppy Brazilian, which will likely be going on gunbroker. I wanted to be sure the modifications went as smoothly as I hoped, before hacking the HE2! (hand ejector 2 on left, Brazilian on right). It rather looks the part too!