What law are you breaking? i understand, OK I really don't, the need or desire or maybe even the thought process behind the desire to be over the top overly cautious but in the absence of actually breaking any laws I cant see what you'd possibly be charged with. All the ATF or anyone else wants to see is that you paid your $200 to register your silencer when you built it and that you filled in the form with some sort of number and that you engraved the can with the right information. No one, including the ATF gives a damn what size holes your baffles have. If thats to much to wrap your head around then call it a 45 silencer and shoot .22's through it. No one gets prosecuted for this stuff because no one cares if you dont break the law.
You are absolutely right that there is no portion of USC that stipulates what range of clearances are acceptable for a given caliber. I'll even admit that it is correct that there aren't ATF agents walking around gun ranges with calipers checking bore diameters against Form 1/4's.
But I've already proposed a situation where the ATF might be wondering what is going on with regards to the bore of a silencer:
pdsmith505 said:
If your papered-as .22 can is attached to your .45 that you just used to stop a mugger, do you really want a prosecutor looking into the possibility that you lied on the Form 1?
The real life, honest to goodness fact is that the ATF's opinion on the matter is:
Q2: May a Federal firearms licensee repair a silencer by replacing worn or damaged components?
A: A person who is licensed under the Gun Control Act (GCA) to manufacture firearms and who has paid the special (occupational) tax to manufacture National Firearms Act (NFA) firearms may replace a component part or parts of a silencer. Repairs may not be done if they result in removal, obliteration, or
alteration of the serial number, as this would violate 18 U.S.C. § 922(k). If a silencer part bearing the serial number, other than the outer tube, must be replaced, the new part must be marked with the same serial number as the replacement part.
The term "repair" does not include replacement of the outer tube of the silencer. The outer tube is the largest single part of the silencer, the main structural component of the silencer, and is the part to which all other component parts are attached. The replacement of the outer tube is so significant an event that it amounts to the "making" of a new silencer. As such, the new silencer must be marked, registered and transferred in accordance with the NFA and GCA.
In the event that identical replacement parts for a silencer are not available, new and different component parts may be used as long as the silencer retains the same dimensions and caliber. In addition, the repair may result in a minimal reduction in the length of the outer tube due to rethreading, but repair may not increase the length of the outer tube. Increasing the length of the outer tube significantly affects the performance of the silencer and results in the "making" of a new silencer. As stated above, a new silencer must be marked, registered and transferred in accordance with the NFA and GCA. Reducing the length of the tube by a minimal amount in order to repair a silencer is often necessary to replace damaged end caps, as the tube must be rethreaded. Such minimal reduction of the length of the tube uses all of the original parts, does not significantly affect performance of the silencer, and may be done as part of a repair process without making a new silencer.
Persons other than qualified manufacturers may repair silencers, but replacement parts are "silencers" as defined in 18 U.S.C. § 921(a)(24) that must be registered and transferred in accordance with the NFA and GCA.
Your thought process is obviously different (specifically, it is less prudent) than mine, but I'll walk you through how I reached my conclusions.
I take the above opinion and reason that the only way to determine what caliber a silencer is is through a measurement of the bore size. There must be clearance of course, but what is reasonable? All the information I've read indicates that somewhere in the range of 0.060" over the bore size is correct. From there, I have two things in my hand: an approved Form 1 with the caliber of the silencer, and the silencer itself.
Now, lets say the silencer is registered and engraved as a .45, but is only bored out to allow a .22 caliber projectile to pass through. It's pretty obvious that either (a) the Form 1 is incorrect or (b) the caliber of the silencer has been changed. If (a) is the case, I'd be worried about the line at the bottom of the Form 1: "Under penalties imposed by 26 U.S.C. 5861, I certify that the statements contain in this Certification, and any attached documents in support thereof, are true and correct to the best of my knowledge and belief." If (b) is the case, then you are running around with what the ATF considers to be an unregistered silencer.
Lets say the silencer is registered and engraved as a .22, but is bored out to the point where a .45 can pass through it without damage. Sure, is is possible that the maker could have grabbed his 1/2" drill bit instead of his 9/32", but it is also possible that somewhere down the line the caliber of the silencer had been changed (b above) or the Form 1 was filled out incorrectly on purpose (a above).
If you found yourself in front of a jury, would you want your freedom relying on the argument that you needed 360% more clearance than is typical to prevent baffle strikes? Do you think that your argument would hold more weight than the engravings on the silencer, the approved form 1, and the testimony of experts?
Food for thought:
26 USC 5861 said:
It shall be unlawful for any person—
...
(d) to receive or possess a firearm which is not registered to him in the National Firearms Registration and Transfer Record
...
(l) to make, or cause the making of, a false entry on any application, return, or record required by this chapter, knowing such entry to be false.
26 USC 5871 said:
Any person who violates or fails to comply with any provisions of this chapter shall, upon conviction, be fined not more than $10,000, or be imprisoned not more than ten years, or both.