Bolt handle milling and threading questions

[missed]

I have a machinist buddy that can do the work for me. I was originally thinking about cutting the end of the bolt off and use a hollow end mill in the mill with the bolt in the vice. I figured the bolt material is hard as can be, they look cast. How are yall doing them? Since I am a lefty I get the short straw on getting complete handles....

[J.Baker]

Best way to do it is to make a fixture to hold the bolt handle in a lathe - that's how Fred did all his before he started having the RH ones cast. Also be forewarned, about 1 in 4 will have a void right where you need to cut the threads to thread on a new knob.

[missed]

These being cast probably have a snow balls chance on welding them too don't they?

I may just have to spend some time behind the computer and do some cad time and get a full billet version made.

[missed]

Do you have any pics of the fixture? I have something in mind but not sure

[sinman]

I tig on new handles all the time, I cut, mill flat and drill a hole for a stub. Tig on and blend out.

[missed]

What filler and pin material are you using? Some 4130 pins and filler? Or 1080 cold roll and er70s? Thanks!

[J.Baker]

Sorry, no pic's of Fred's fixture and it's been so long since I've seen it that I don't even want to attempt describing it.

[stangfish]

I cut, mill flat and drill a hole for a stub.
Yep. Only in this example both pieces were tapped and joined with a piece of all thread. Sin mans way is best but he is set up a lot better than I am.

From this
http://i1202.photobucket.com/albums/bb363/stangfish/Stuff/51d7ecb5-62f4-4780-acd6-e979ae813934_zps3b5ebdda.jpg

To this
http://i1202.photobucket.com/albums/bb363/stangfish/Stuff/e923386d-518a-46b7-adb4-1c4c6e0a4c95_zpsf8720ef2.jpg

[bootsmcguire]

+1 with Sinman and Stangfish. Here are a couple of pics of the ones I have been making for my rifles. I just cut off the handle, and then I have been drilling and tapping the base of the old handle and then threading the stub on the new handles shaft.

http://i747.photobucket.com/albums/xx111/bootsmcguire/100_4555.jpg (http://s747.photobucket.com/user/bootsmcguire/media/100_4555.jpg.html)

And here's one showing (top to bottom) a Savage BT, a SSS Tactical Handle, and two of mine. You can see the joint and location of where to cut off the factory handle.
http://i747.photobucket.com/albums/xx111/bootsmcguire/bolthandles.jpg (http://s747.photobucket.com/user/bootsmcguire/media/bolthandles.jpg.html)

And here is one that's been installed as Sinman described above.
http://i747.photobucket.com/albums/xx111/bootsmcguire/Boots%20Bolt%20Handles/SinmansBootsBoltHandle.jpg (http://s747.photobucket.com/user/bootsmcguire/media/Boots%20Bolt%20Handles/SinmansBootsBoltHandle.jpg.html)