So you want to by a S&W???

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Just for convenience, linking the pictures from ambackforum:

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I'm not sure why they failed from looking at the pictures (pretty small), but the surfaces look similar to a fatigue failure (it's not, though). The smooth portion from crack propagation, then the rough looking portion from the last little bit being torn away as that was the last shot the barrel could take. At the very least, some sort of error during assembly or maintenance produced a crack in the barrel. The posts about the torque tightening producing a crack seem like the best bet.
 
Maybe that is where Ruger got their idea for the Alaskan.
I think the cause is those prison guards have been doing some pistol whipping.
I would suggest an 8 inch barrel for the replacements---more leverage.
 
Hey! Not fair to not tell what the lube is that could cause this! Though, I think I may have an idea...and, if so, I use it regularly.
 
I'd skip the user application of dangerous solvents as the answer.

That one revolver shows a total of 4 rounds fired prior to the barrel being launched.

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I'd subscribe to the theory that the barrel/shroud/frame system was overtorqued upon assembly. That may be a specific problem for the new shrouded barrels.

However, as I look inside the barrel of my 3" L-Frame 696 from the forcing cone end, I do see an obvious ring in the barrel, most prominent on the right side of the bore as one looks forward through the barrel. It sits in the barrel at the approximate location where the threaded barrel's shoulder meets the frame, about 0.250" forward of the forcing cone's breech face. (That would be right about where those Model 65 barrels broke off in the pictures above) As one follows the ring around the bore, it almost disappears on the left (9 o'clock) side of the bore. Sorry for the poor pictures, but the macro of my digicam isn't the best thing in the world, especially when I'm also using a point source LED flashlight to illuminate the problem area inside the barrel:

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Now, the 696 is the older single-piece barrel, not pinned, but I'm certain there was a certain torque value needed to time it correctly. Granted, this is a .44 Special L-Frame, and the barrel wall thickness would be fairly thin compared to a .38 Special/.357 Magnum. Heck, just look how thin the forcing cone is!

To date, I've run about 300 cast-bullet rounds through this gun since I bought it, and I noticed the ring from day one. I've watched it closely, it hasn't grown or gotten more pronounced, and the gun shoots very nicely, both accurately and smoothly. I suppose I could bring it to Smith & Wesson's attention, but I'm afraid they may not fix it, and instead offer me something with the lock pimple and frame-mounted firing pin in return.
 
I'm still waiting for a misfire or something to break on my Ruger KGP-141. I'll let everyone know if anything negative ever happens.;)
 
That one revolver shows a total of 4 rounds fired prior to the barrel being launched.

Is that correct? I thought every other chamber was test fired on new S&Ws. I used to occaisonally clean the face of my old 686's cylinder with Flitz back in the day.

That may be a specific problem for the new shrouded barrels.

Are these two-piece barrels? None of the pictures I've seen give a good enough look at the muzzle end.

However, as I look inside the barrel of my 3" L-Frame 696 from the forcing cone end, I do see an obvious ring in the barrel, most prominent on the right side of the bore as one looks forward through the barrel.

I've read about these barrel constrictions from time to time (not just in S&Ws). Some folks lap the barrel or do Taylor throating to remove them, but I get the impression that if you're not having a problem accuracy-wise, it's not a big deal.
 
Boats beat me to it: Instead of asking S&W to make special runs, buy Rugers and never worry about a failure!
 
In the meantime, another problem emerged: barrels dropping or flying off the Model 65s during firing. The department surveyed trainers across the state and counted up 14 cases of barrel failure in the past three years.



I knew they should have never stopped putting those pins in the barrels :)
 
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