Shotgun muzzle device dilemma.

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Acera

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Situation, got a Beretta 1201 FP used mainly as a home defense shotgun and a Wad Wizard breacher, on a truechoke tube.

What I want to do: Fit them together on my shotgun.


Why is this a problem? Well there is not enough metal in the barrel to allow for it to be threaded for the choke tube. Not enough barrel to cut it back far enough to get enough metal and still stay legal without a stamp, or other real problematic issues.

When the breaching device is removed from the choke tube, the ID is larger than the OD of the barrel.

First possible solution, which I am sure will be favored by many, is to forget the whole project. That I have tried for years, and keep coming back to it every time I see the part in my box.


Second solution I have thought about is to use the parts available and make a mounting system (ring) for it on the outside of the barrel. That is what I want some expert help in determining if possible.


Where the device would be mounted, the barrel OD is: 0.810

The ID of the part of the choke where the device screws on it is: 0.714

The OD of the part of the choke where the device screws on it is: 0.875

The OD of the part of the choke where the device screws on it at the bottom of the threads is: 0.820

I was thinking about cutting off the choke threads flush with the start of the threads for the device.

Then I figure if I get the part machined out to the exact same ID as the barrels OD, I should have about 0.106 solid metal left.



Next issue, the front sight base may have to be cut back to the edge of the sight insert (or notched out). That way I get the maximum amount of purchase on the barrel I can without relocating the front sight. Figuring about 0.51 total, or about 1/2 that if I don't cut the front sight base.

I was thinking about heating the part with a torch, while cooling the barrel in a bucket of dry ice to get enough expansion and contraction to allow the parts to fit together and hold in place. Final thoughts on adhesion of the two parts might involve loctite during fitting or silver solder after fitting to make a good joint. Is having the same dimensions a good idea, or should I make the ID of the part a little bigger than the OD of the barrel?


End result is the device would be able to screw onto the new threaded collar on the end of the barrel, and fit tight up against the front sight post and be functional.

Does this sound like it would work?


Any other suggestions on how to make it work?

Just hoping that there is enough metal that it will hold up to regular firing and on occasional close up use. I have faith in the device itself, want to have the same level of faith in the mounting system.




Sorry for the crappy cell phone picture, hope it helps explain my issues.
wadwuzard1_zpsutg6b7bc.jpg
 
Interesting Idea Jim,

But........................

It does not look like it fits the truchoke (Remington???) system I have and I am not interested in turning the barrel making it thinner than it already is. But it is a good idea. I checked out Colonial Arms website, but not much there.



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