Cutting down a barrel

[Drachen]

So I recently picked up a OTP barrel kit that came with two fronts, a 14" and 16".

I was curious about how difficult it would be to have the 16" cut down to a 12" with not much beyond hand tools. Obviously I'd need to home out the tip of the barrel after the cut, but is there much beyond that? I've never really done any kind of customizing of any kind besides swap parts here and there.

Also, on another question. Does anyone know how to separate the front and back of the OTP G3 barrels? Looking at the spare front it looks like they're just pressed together, but it looks like there was some sort of adhesive on it at one point which makes it look like it might be a little tough to separate. I was thinking of putting a couple strap wrenches on the front and back and try to muscle it off, but in sure there's an easier way to do it.

[BrickHaus]

Ideally, Id want to spin the barrel to make the cut to keep it even. If you are talking hand tools only youd want to make a jig with a wood dowel that fit snug in the barrel, then was just small enough to fit in your largest hand drill chuck. If you have a big old school hand drill id say a drill that chucks on 1" bits is ideal. Then sand a piece down to fit in the barrel, and chuck the other end up in your super drill.

Then id rotate the barrel while carefully making the cut with either a hack saw blade or a cut off wheel spinning itself.

Then chamfer the barrel tip.

[Señor Leo]

A few months back I cut down a barrel. First, I wrapped some blue painters tape around the area that I wanted to cut down. Next, I marked where I wanted to cut and used a hacksaw to make the cut. After, I sanded it with the tape still on. It actually came out way cleaner than I expected. Later on today Ill post a picture of how it came out

[scottieb]

On the front and back of the OTP barrels - they are glued and pressed together. I imagine you'll need heat to separate the two. Regular hand tools will mar it something terrible.

[scottieb]

I've not done this before however if I were to attempt, I'd try letting it sit in an oven for a bit or applying the open flame to the stainless back only.

[Drachen]

How high of heat in the oven are we talking? I have never tried to separate barrels before. I'd hate to cause damage to the barrel or oven...

[scottieb]

Again, I've not done any oven work like this. I'd imagine 350* is a great temperature to use. I wouldn't worry about harming either the barrel or the oven.

[Alexndl]

I cut down this freak tip couple of month ago using a pipe cutter (one for copper)
Take your time, start slow to make the initial groove and not too much pressure each time. I do 2 full turn and increment the pressure with the knob 1/2 turn and repeat.
Aluminium is not that hard to cut.
I put painter tape to prevent the roller from marking, use a deburring tool and sand paper to clear the burr inside the cut afterward

it will show depending on the anodise color but I dont think it look too bad and can use sharpie to cover the cut.

[Alexndl]

The VASA have NPT hole on both side and a second macroline go from the VASA to the rear of the firing can
Similar to an automag

[autococker04]

I didn’t even know what I was looking at until I read the comments

[Jordan]

It's a cool sleeper - hard to tell it from a Mag at first glance.

[MAr]

Cut with Rigid pipe cutter.

[Memornix]

+1 for the pipe cutter. I would say send it to me and I could do it, but I know the journey that barrel has already taken

[Drachen]

Yeah no kidding. They are so slow it would be March by the time I get it back.

When I bought it, my brain wasn't working right and I thought the inserts went into the back of the black front. Not that the black was indeed actually a front lol. Oh well, get to try a new project now.

[Drachen]

So after doing a few practice cuts on a random Mini barrel in the bin, I got it cut and deburred. Might get some sand paper to make it a little more smooth. But it doesn't look bad at all.

Would it be fine to leave the tip of the barrel raw, or should it be coated before use?

[Alexndl]

Raw tip should be fine

But we need picture to see the end result before we can confirm 😄