Terrible flame cutting problem

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I have worse on a number of pistols. Absolutely freaked me out, thought the frame strap was going to be cut through. Didn't happen.
 
Howdy

That flame cutting does not look so bad to me.

Here is some flame cutting under the top strap of one of my 2nd Gen Colts. This one has had thousands of Black Powder 45 Colt rounds through it.

blackpowdertopstraprelief2ndGenColt_zps1fa8f1f0.jpg




This is the flame cutting on a 38-40 Bisley Colt made in 1909.

blackpowdertopstraprelief38-40Bisley_zps09598f22.jpg




You will notice on both of these revolvers the thumbnail shaped relief cut just behind the barrel. This cut was put there to give space for Black Powder fouling to build up without binding up the cylinder. The cut is pretty useless, I have fired thousands of rounds of Black Powder through the 45 and have never seen the relief cut fill up with fouling.

Regarding opening the barrel/cylinder gap: I would recommend against it. But you already did it, so I am too late.

In my experience opeining up the b/c gap just allows more fouling to be deposited on the cylinder face and cylinder pin, causing binding to happen sooner, not later. But I am too late, you have already cut it.

A cylinder gap of .004 with .002 endshake, which is what you have, is fine. Don't mess with it any more.
 
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