The result is a neat pin installation that includes epoxy-lined holes for the pins that experienced the most wear and tear in use. As their thread fit is so poor in the 8-32 holes of the percussion lock, I decide to replace the lock bolts. Here I have the original, undersize bolts and two pair of replacement candidates to find the set that fits the lockplate threads best. Not all storebought bolt threads are exactly the same. As the new bolts have thicker shafts, I measure and hand-ream the stock holes and trim the new bolts to length.
All screw holes in the wood are coated with thin cyanoacrylate glue to strengthen the threads. This is especially important in screw holes drilled into end grain, a naturally weak construction. The screw beneath the breech plug that mounts the front of the wooden trigger guard was so deteriorated that I replaced it, to include filling the end-grain pilot hole in the fragile guard with dyed epoxy and redrilling it when I fitted the guard.
Before I installed the barrel I mounted and aligned the sights using an optical boresight, and carefully refitted the patch box lid and spring, scraping off finish as required and waxing the lid for ease of use.
The last step is mounting a replacement folding tang sight. This one is an American sight, and mounts slightly differently, but is of the correct period and is adjustable for windage as well as elevation. I will fabricate a base that doesnt alter the stock and make the mounting fully reversible should I ever find the correct sight. Here Im drilling and tapping a section of drill rod for the 12-64 threads of the sights shaft, and shaping it to fit the existing sight mortise in the stock.
Once the new base is shaped and fitted to the shaft, I mount it by filing corresponding grooves in the shaft and the inside of the stocks mortise using file and Dremel tool, and after applying release agent to the shaft, glue the assembly to the stock using thickened epoxy. When the time comes, holding a hot soldering iron against the sight until it reaches 200 degrees or so will release with without damaging the stock, and Ill have an epoxy-lined hole to work with in mounting a more correct tang sight.
Test firing the boresighted Jaeger took several shots to get the load in the ballpark. Although these are of large caliber, the old-fashioned barrel twist of one full turn in the barrels length is so fast that what would be a normal charge for later patched-ball rifles destroys the patch, the gas seal, and the accuracy. I settled on half the charge one would expect - 60 grains of FFG, a .580 ball with tight, double-patching using .010 prelubed patches, and you can see the difference between inner and outer patches. Test firing was well worth the effort, as I had the frictionless, fly-tumbler lock and set trigger set up too loose, and had to make some adjustments to insure a safe gun. I didnt chronograph these, but it appears accuracy will be excellent without any further barrel work, and the load fires with enough authority to bruise the shoulder after less than a dozen shots.
All in all, a worthwhile effort, and I look forward to incorporating this jaeger into my school and even my shooting demonstrations.
