Completed Project:

We were thrilled to complete this muzzleloader project today. It's now a stunning piece, both at a distance and close up, and has demonstrated remarkable accuracy. Please continue on below to learn more about the recondition process.


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A friend left this to be refurbished without providing any details. It's a good-looking half stock, but it seems to conceal some significant but fixable issues. Sometimes, an attractive rifle can distract you from the underlying problems. In this example she's definitely worth fixing. While it appears to be very similar to a kit build something about it feels much older.


Specifications:

• Caliber: 45 (measures .449 inches)

• Total length: 50 inches

• Barrel Length: 33 inches

• Weight: 7.8 pounds

• Barrel Weight: 5.8 pounds

• Barrel Type: Twist Rifling

Initial review:
This rifle is visually appealing, but it only holds up from a distance — the 10-foot rule applies here, as its current condition is less than ideal. There's no sign of maker's marks or proofing, suggesting it might be a product of a small-scale or home gunsmith. The stock has been stained to mask flaws, and a section near the lock has been replaced, indicating significant use and age. The wood is dry, varnished, and shows several cracks and fractures, likely from years of hunting. The lock mechanism, while present, is in rough shape due to rust and wear, with faint, almost unnoticeable marks on the lock plate. It operates, but clumsily, with loose parts and weak spring tension. The trigger guard, secured by a broken pin, has been bent for makeshift repairs, and the rear trigger doesn't stay engaged without precise handling, pointing to issues with spring tension and alignment. The barrel shows rust pitting that needs addressing, and it's next on the list for inspection. Despite its current state, with some effort, this rifle could be restored to its former glory. I believe it's worth the investment.

Step 2 . Time to clean it up and see what we can do.
The barrel looks nice except for the area near the powder drum and nipple. There must have previously been a buildup of rust that was repaired or a result from the conversion from flintlock to percussion. It appears to be still strong enough, but I really don't like it. We're thinking about laying down some strapping welds and slowly build it up without adding too much heat.


The barrel exterior otherwise looks to be in good condition. I did run a cleaning brush down the interior of the barrel and felt it twist indicated a rifled barrel. We still haven't had a chance to run a scope down the barrel but it's on the list of to-dos.

All of the remaining metal components went for a bath, and nonabrasive cleaning and are looking good without the grime and rust.

Once cleaned, the markings on the lock plate's face are more visible, but they don't help in identifying the rifle.


The lock size measures roughly 4.7 inches, and I think that is our best hope to identify.

After a little research we did find that R.E. Davis Co. makes a percussion lock that measures about that size and looks promising.
It appears this lock design is designed on the Jim Bridger's Hawken percussion lock. https://www.trackofthewolf.com/Categori ... /lock-jb-r

Here is an image comparing the rifle's lock compared to the R.E. Davis lock sold on Track of the Wolf.
This sure looks close but still not an exact fit in terms of mount/screw locations. They report "Designed by Ron Long, this famous lock was used by Green River Rifle Works of Roosevelt, Utah, on their Jim Bridger Hawken rifle."

I think we're getting closer but to dig a little deeper.

The Ron Long Percussion lock is a notable component in the world of muzzleloading firearms, particularly known for its association with Hawken-style rifles.

• Origin and Production: Ron Long, based in Denver, was known for creating locks during the 1970s and 1980s. His locks, including the percussion version, were part of kits or sold individually, contributing to the custom building of rifles.

• Design Features:
  Hawken Style: The Ron Long Percussion lock is a reproduction of an original lock, designed to match historically accurate Hawken rifle locks. It includes a polished tumbler with fly and sear, indicating a focus on quality and functionality.

• Dimensions: The lockplate measures 4 7/8" x 1" in its left-hand version, tailored for use with hooked breech systems but adaptable for drum installations with some modifications.

Here is a comparison of the rifle's lock to a Ron Long percussion lock:
It's close but still not an exact match from what I'm seeing. I'm going to see if I can figure out who Ron based his design on.

I found another muzzleloader thread that references a hawken rifle with a lock by a Joseph or Josh Golcher: https://www.muzzleloadingforum.com/thre ... os.141421/

The usage of Joseph and Josh appears to be tying back to the same individual however we have not yet confirmed that. Maybe Josh was a nickname.

The lock plate engraving trim appears very similar and maybe worth a dig. Josh Golcher was a notable gunsmith in the 19th century, particularly recognized for his work in manufacturing locks for muzzleloading firearms. Here's a detailed overview based on the available information:

• Time Period: Josh Golcher was active during the first half of the 19th century, with his locks being documented from approximately 1820 to 1860.

• Location: He was based in Philadelphia, Pennsylvania, a hub for gun manufacturing at the time.

• Specialization: Josh Golcher specialized in producing high-quality percussion and possibly flintlock mechanisms for rifles and shotguns. His locks were known to be used by other gunsmiths for assembling complete firearms, indicating a level of respect for his craftsmanship within the gunsmithing community.

• Kentucky Long Rifles: There are mentions of Kentucky long rifles equipped with locks made by Josh Golcher. One example includes a rifle from this period with a lock bearing his name, showcasing detailed engravings like game bird scenes.

• Engraving and Quality: His locks were often engraved, with descriptions of his work including rococo scrolls and other decorative elements, indicating a focus on both functionality and aesthetics.

After a quick search I didn't find an example with this type of lock but here is a Golcher lock that did use oval symbolism (here it's used twice). I think we're getting warmer!

Here is a picture of the faceplate of the lock of this rifle with red highlights. It is now clear that the lock was converted from flintlock to percussion at some point in the past.
I think this is what it is supposed to look like:

Here is another with the full name Joseph:

Given that this is a black powder rifle with lower pressure demands, we chose to gradually reinforce the steel.
The images show a before and after comparison of the area around the powder drum on a black powder rifle.

Top Image (Before):

• The metal around the powder drum appears worn, with visible signs of use such as pitting, rust, and general wear.

• There might be some deformation or damage around the drum area, indicating potential stress or impact.

Bottom Image (After):

• The area around the powder drum has been reinforced, using strap welding techniques.

• The surface looks much smoother, with the metal built up to strengthen the area without compromising the structural integrity of the rifle.

• This reinforcement should help in extending the life of the rifle by preventing further wear or damage in this critical area.

This restoration or modification approach aims to preserve the functionality and longevity of the rifle.

The dual set triggers were not holding correctly and it turns out that the trigger return spring was worn out and not strong enough to set.

You can learn more in a topic here: https://jcastaway.com/collaborate/viewt ... a63b6b397f

The hole for the rear trigger guard pin was damaged and unusable when we received it. This area is crucial as it experiences stress and is essential for maintaining the trigger assembly.


We concluded that the optimal method was to mend it with fiberglass and filler, attempting to hide the repair as much as possible. Typically, we'd strengthen it with wood shavings from behind the butt plate, but that wasn't an option this time. It's quite an unpleasant sight I must say. We suggest applying lubricant to the wood in areas where you wish to avoid filler; this simplifies shaping without damaging the wood. The pin and trigger guards were coated in wax, and we removed them just as the filler began to harden.


Below is a photo of the repair prior to airbrushing. We'll provide an update once we've better masked, but for now, it's completely operational, allowing for quick trigger maintenance. Honestly, when you handle the weapon, the repair is barely noticeable, so I believe it will end up looking fantastic.

We're getting ready to bring her back to life today! One final barrel inspection and all looks good.