Wednesday, April 23, 2014

Building an inexpensive Home Defense Shotgun

This is an update from an earlier post called : Shotguns!.
I bought this shotgun from a guy on SGN for $40, it was rusty and was missing the trigger group. It is a Sears model 200, which was actually a brand labeled Winchester model 1200.
 These were "economical" shotguns, designed to be more affordable versions of the Winchesters. The wood was birch or some other cheap wood. The receiver is aluminum (same as the Win 1200) so a complete re-blue was out.
I was able to source a trigger assembly from another SGN member (thanks again Don!). 
I then shortened the barrel to just under 19". I sanded both the wood & metal & painted the metal flat black and the wood flat olive drab.
I added a side saddle that I paid $10 for at the gun show.

 I then found an extended magazine tube kit for $15 including shipping. The mag tube kit increased the mag capacity from 5 rounds to 8. It also turned out to be longer than the barrel. This doesn't present a problem when shooting, many competitive shotgun shooters have mag tubes that are longer than their barrels, Here is Jerry Miculek's shotgun
 It just looks weird to me. 

 I thought about buying a "Stand-Off" device.
The Stand-Off device was designed for Riot teams to use as a non-lethal weapon, to be applied to crowds that are getting too close. They are also used for door breaching guns as a means to "lock" the gun to the door wood.

Here are some examples of Stand-Off devices:

These devices sell for $30-$90 and up. In keeping with the budget minded theme, I decided to make my own.
My new mag tube stuck out about 2 1/4" from the muzzle. 
 Adding the Stand-Off will also hide the hideous cut job I did on the barrel....
I found this piece of 3/4" pipe in my garage, the barrel will almost fit inside, which is perfect. I will grind the inside 1-2" in and make a tapered fit for the barrel. The dimensions of the pipe are roughly 1.07" OD, .825" ID and about 3/32" thick
I cut a piece 3 1/4" long

I used the Dremel to clean up the insides and remove the seam and did a trial fit, the fit was tight, I almost couldn't get it back off

Then I cut vertical lines with the hack saw

Then I used the hack saw to make angle cuts
 It looks pretty knarly, I'll clean up the edges with a file

In the mean time I noticed that the mag follower would not exit the top of the original mag tube on its own. There was some sort of restriction. I'm not sure if the mag tube had a dent (I couldn't see or feel one) or if it was designed that way. I sanded and polished the mag follower unit it moved freely in both mag tubes
 The barrel/Mag clamp that came with the kit did not fit, luckily I had this ATI clamp that fit perfectly
 Here is the completed gun, looks pretty good now, but the stand off device is not up to par...

I decided to '86' this disasterpiece and looked into buying a pre-fabbed one. Oh well nothing ventured, nothing gained, right?

I enlisted the help of my buddy (he goes by Tactical Assault on WaGuns and SGN ).
He is a machinist and a very talented one at that.
This is what he made me:

In conclusion here is the break-down of what this gun cost me:
Shotgun: $40
Side-Saddle: $10
Trigger Group: $0 (although if I did have to buy one, I could have found one for around $50 on ebay or gunbroker)
Extended Magazine kit: $15
Stand-off Device: $50

Grand total: $115

Not too shabby! So the next time you see a rusty gun, missing parts for cheap, don't pass it by, give it a second look, you might be able to score something great!