[Gryphon43]

Hey guys, I need some help.

I just got an original Merlin kit full of pieces, new in box.

All the parts are anodized a beautiful dust champagne color.

The problem is, when I went to assemble the gun I noticed that the hammer will not fit into the bottom tube because all of the holes (i.e.grip frame screw holes, valve retaining screw hole) have a lip on the inside.

It seems the bottom tube was not reamed after the holes were machined.

My question is, what are my options?

[TheePsycho]

Send it to Jared at DC or Super Stanchy Customs, Rainman, Jcurt or KPCS should all be able to help you out. Even a local machine shop could help you clean up the lower tube or do it at home.

Pictures always help.

[Gryphon43]

I thought about that, but that will leave the inside of the bottom tube raw aluminum.

[PumpForLife]

I'd take it to a machinist and have them use something like a flex-hone on it.

[Gryphon43]

I'm going to try putting a small dovetail cutter in the hole from inside, then grabbing the shaft (hehe dirty) with a drill. this "should" do the least amount of damage to the anodizing.

I'll try to take some pics to show you the problem.

[MeuroM]

I would suggest not doing that. An adjustable reamer is what I'd use. You can adjust it to be just a hair under the bore size and pass it through manually. That should not scrape the ano off the tubes and will remove the unwanted lips. I did something similar lately and it worked well.

[Gryphon43]

I found a tiny dremel conical sander. I removed the head and dropped it into the hole from inside the body and reattached it to the shaft. Then just spun it with my fingers.

This worked perfectly, there is just a hair thin line of exposed aluminum on the front and back of the hole.

Problem solved!!