The M1911 Complete Assembly Guide – Table of Contents

In this book you’ll learn about Pistolsmithing, the M1911 magazines, triggers, stops, locks and history – and much more.

Inside: The Model of the 1911 was designed to be a “battle pistol.” The M1911 was adopted by the US Army in 1911 largely on the basis of successfully weathering stringent testing, including environmental testing. These “dust and rust” tests  were surmounted by the M1911 despite the metallurgy of the 1910 by providing sufficient clearances for contaminants to be literally “shrugged off.” Thus, while the original M1911s may not have rattle like maracas as legend would have it, they were designed to be loose enough to tolerate dust ‘n rust and mud ‘n blood. What they weren’t designed to be, was target pistols. that was to change, thanks to the National Matches.

Table of Contents
By Walt Kuleck with Drake Oldham

CHAPTER 1: The Purpose of This Book…………………………………………………………… 1

The Purpose of This Book……………………………………………………………………… 1

We Were Not Alone……………………………………………………………………………… 2

In Closing…………………………………………………………………………………………….. 2

Please Help Support……………………………………………………………………………………. 3

CHAPTER 2: A Brief History of Pistolsmithing…………………………………………………. 5

The First Pistolsmith………………………………………………………………………. 5

Bullseye Competition…………………………………………………………………….. 7

The Post-WW II Era………………………………………………………………………………… 9

Service Pistols……………………………………………………………………………….. 9

NRA Match Pistols…………………………………………………………………………. 13

Barrel Firing………………………………………………………………………………….. 15

Practical Pistol………………………………………………………………………………. 21

Improved Sights………………………………………………………………………. 23

Thumb Safeties/Safety Locks…………………………………………………….. 27

Extended Slide Stops………………………………………………………………… 27

“Beavertail” Grip Safeties…………………………………………………………. 27

Hammers………………………………………………………………………………… 29

Long Slides………………………………………………………………………………. 29

Ramped Barrels……………………………………………………………………….. 31

Triggers…………………………………………………………………………………… 31

Barrel Bushings………………………………………………………………………… 33

Compensators and Barrel Weights…………………………………………….. 33

Miscellaneous Upgrades………………………………………………………………… 37

Full Length Guide Rods (FLGRs)…………………………………………………. 37

Lowered and Relived Ejection Ports…………………………………………… 37

Extended Magazine Catches……………………………………………………… 37

Extended Ejectors……………………………………………………………………. 37

Dead Ends…………………………………………………………………………………….. 39

Square Trigger Guards………………………………………………………………. 39

Ambidextrous Slide Stops…………………………………………………………. 39

“Chopped and Channeled” Government Models…………………………. 39

Double Action Conversions……………………………………………………….. 41

Swaged Magazine Wells……………………………………………………………. 41

Pistolsmithing Today……………………………………………………………………………. 41

CHAPTER 3: How to Use This Book……………………………………………………………….. 45

How to Use This Book…………………………………………………………………………… 45

Purpose……………………………………………………………………………………….. 45

What You’ll Need………………………………………………………………………….. 45

Workspace…………………………………………………………………………………… 45

Basic Tools………………………………………………………………………………………….. 45

Bench…………………………………………………………………………………………… 45

Vise……………………………………………………………………………………………… 47

Hand Tools…………………………………………………………………………………… 47

Files, Stones, and Sandpaper…………………………………………………….. 47

Marker……………………………………………………………………………………. 49

Hammers………………………………………………………………………………… 49

Punches………………………………………………………………………………….. 49

Bench Block…………………………………………………………………………….. 49

Tactical Light…………………………………………………………………………… 49

Recommended Items…………………………………………………………………….. 49

Magnifier………………………………………………………………………………… 49

Dummy Rounds……………………………………………………………………….. 51

Trigger Pull Gauge……………………………………………………………………. 51

Loose-Fit Barrel Bushing…………………………………………………………… 51

Power Tools………………………………………………………………………………….. 51

Drill Press………………………………………………………………………………… 51

Belt Sander……………………………………………………………………………… 51

Dremel Tool…………………………………………………………………………….. 51

Nice to Have, But…………………………………………………………………………… 53

Pin and Square Gauges and/or A Numbered Drill Bit Set………………. 53

Dial Indicator and Fixtures………………………………………………………… 53

Specialty Tools………………………………………………………………………………. 53

Measure Thrice, Cut Once…………………………………………………………………….. 53

Safety First!…………………………………………………………………………………………. 53

Having Fun and Gaining Pride and Satisfaction………………………………………… 55

CHAPTER 4: Getting Started…………………………………………………………………………. 57

Getting Started……………………………………………………………………………………. 57

Have a Plan…………………………………………………………………………………… 57

Start Modestly………………………………………………………………………………. 57

Have a Purpose…………………………………………………………………………….. 57

Gather the Resources…………………………………………………………………….. 58

Be Realistic…………………………………………………………………………………… 58

Get Started………………………………………………………………………………………….. 58

CHAPTER 5: Frame and Slide Fitting……………………………………………………………… 59

Frame and Slide Fitting…………………………………………………………………………. 59

Basic Principles for an Oversize Frame……………………………………………………. 61

Star with a “Road Map”………………………………………………………………………… 61

File and Fit: Slide Rail Sides……………………………………………………………………. 63

Frame and Slide Pre for Fitting………………………………………………………………. 63

Frame-Slide Lapping…………………………………………………………………………….. 65

Now for Some Fine Points………………………………………………………………. 73

A Sticky Slide…………………………………………………………………………… 73

Is the Frame “Flat”?…………………………………………………………………. 73

Four Point Contact at Lockup…………………………………………………….. 73

Basic Principles for a “Clearance-Fit” Frame……………………………………………. 73

Start with a “Road Map”……………………………………………………………………….. 75

Narrowing the Frame Groove………………………………………………………………… 75

Overview……………………………………………………………………………………… 75

Example……………………………………………………………………………………….. 77

Aftermath…………………………………………………………………………………………… 81

CHAPTER 6: Grip Safety Installation………………………………………………………………. 83

Grip Safety Installation…………………………………………………………………………. 83

Why Now?……………………………………………………………………………………. 83

Why “Install” and Not “Fit”?…………………………………………………………… 83

Installing the High-Rise Grip Safety………………………………………………………… 85

Roughing Out the Tangs…………………………………………………………………. 85

Lapping-in the Grip Safety………………………………………………………………. 91

Blend the Back Straps and the Grip Safety ………………………………………. 97

CHAPTER 7: Barrel Fitting…………………………………………………………………………….. 103

Barrel Fitting……………………………………………………………………………………….. 103

General Considerations: Barrel Contact…………………………………………… 103

General Consideration: Type of Barrel…………………………………………….. 103

Drop-in…………………………………………………………………………………… 103

Easy-Fit by Kart………………………………………………………………………… 105

Gunsmith Fit……………………………………………………………………………. 105

Recommendation………………………………………………………………………….. 105

Begin by Fitting the Barrel Bushing………………………………………………………… 105

Fitting the Barrel Hood to the Slide………………………………………………………… 109

Lateral Fit……………………………………………………………………………………… 109

Longitudinal Fit……………………………………………………………………………… 113

Headspace Check…………………………………………………………………………………. 115

Fitting the Locking Grooves…………………………………………………………….. 117

Fitting the Barrel to the Frame……………………………………………………….. 123

Lower Lugs to Frame Fit…………………………………………………………………. 123

Check for the Bow Tie……………………………………………………………………. 123

Fitting the Lower Lugs (Barrel Feet)……………………………………………………….. 125

General Considerations………………………………………………………………….. 125

Fitting the Lugs to the Slide Stop pin……………………………………………….. 125

Pre-fitted Barrels and Kart Easy-Fit Barrels…………………………………… 125

Installing and Fitting the Barrel Link………………………………………………… 129

Conclusion………………………………………………………………………………………….. 131

CHAPTER 8: Assembling the Slide…………………………………………………………………. 133

Assembling the Slide…………………………………………………………………………….. 133

General Considerations………………………………………………………………….. 133

Firing Pin Stop……………………………………………………………………………………… 133

Extractor…………………………………………………………………………………………….. 135

Prepping the Extractor…………………………………………………………………… 137

Installing the Extractor…………………………………………………………………… 137

Adjusting Extractor Tension……………………………………………………………. 139

Qualitative Method for Adjusting Extractor Tension…………………….. 139

Quantitative Method for Adjusting Extractor Tension………………….. 139

Final Extractor Check……………………………………………………………………… 141

Firing Pin and Firing Pin Spring………………………………………………………………. 141

General Considerations………………………………………………………………….. 141

Installation (no firing pin safety)……………………………………………………… 143

SERIES 80 SLIDE ASSEMBLY……………………………………………………………………. 143

General Considerations………………………………………………………………….. 143

GOTCHAS!…………………………………………………………………………………………… 149

Slide Hood Recess…………………………………………………………………………. 149

Barrel Tunnel………………………………………………………………………………… 149

CHAPTER 9: Sight Installation……………………………………………………………………….. 151

Installing the Rear Sight………………………………………………………………………… 153

Installing the Front Sight……………………………………………………………………….. 157

Dovetail Type……………………………………………………………………………….. 157

Tenon Type…………………………………………………………………………………… 157

Peening and Swaging…………………………………………………………………….. 159

CHAPTER 10: Frame Assembly – Internal………………………………………………………. 165

Assembling the Frame: Internal Components………………………………………….. 165

General Considerations………………………………………………………………….. 165

Magazine Catch Installation……………………………………………………………. 165

Trigger Installation (Physical Trigger)……………………………………………….. 169

Trigger Bow…………………………………………………………………………….. 169

Trigger Shoe……………………………………………………………………………. 173

Fitting the Fire Control System……………………………………………………….. 175

Background…………………………………………………………………………….. 175

Prepping the Hammer………………………………………………………………. 175

Prepping the Sear…………………………………………………………………….. 177

Fitting the Hammer and the Sear; the “Trigger Job”…………………….. 177

Disconnector Prep……………………………………………………………………. 181

Sear Spring……………………………………………………………………………… 181

Installing the Fire Control System……………………………………………………. 181

CHAPTER 11: Frame Assembly –  External………………………………………………………. 189

General Considerations………………………………………………………………….. 189

Ejector Installation………………………………………………………………………… 189

Plunger Tube Installation……………………………………………………………….. 193

Thumb Safety Installation and Fitting………………………………………………. 197

Fitting the Sear Block……………………………………………………………….. 199

Fitting the Detent…………………………………………………………………….. 199

Grip Safety Fitting………………………………………………………………………….. 201

Raising the Bridge…………………………………………………………………….. 201

Lowering the River…………………………………………………………………… 201

Mainspring Housing Assembly and Installation…………………………………. 203

Grip, Screw and Bushing Installation……………………………………………….. 207

Conclusion………………………………………………………………………………………….. 207

CHAPTER 12: Final Assembly and Inspection………………………………………………….. 209

Recoil Spring, Recoil Spring Guide and Recoil Spring Plug…………………………. 209

Slide Stop……………………………………………………………………………………………. 209

Safety Checks………………………………………………………………………………………. 211

Thumb Safety……………………………………………………………………………….. 211

Grip Safety……………………………………………………………………………………. 212

Disconnector………………………………………………………………………………… 212

Dry Fire Function Check (the Pencil Test)………………………………………………… 212

Series 80………………………………………………………………………………………. 213

“Swartz” – Type Safeties………………………………………………………………… 215

50 Round Function Check……………………………………………………………………… 215

Appendix 1: CERAKOTE……………………………………………………………………………….. 217

Why Cerakote?……………………………………………………………………………………. 217

What You Need to Finish with Cerakote…………………………………………………. 217

The Seven Steps to a Perfect Finish………………………………………………………… 217

Getting Started……………………………………………………………………………………. 219

Step 1: Completely Disassemble……………………………………………………… 219

Step 2: Clean and Degrease……………………………………………………………. 219

Step 3: Grit Blast……………………………………………………………………………. 219

Step 4: Blow Clean………………………………………………………………………… 221

Step 5: Outgas………………………………………………………………………………. 221

Step 6: Spray………………………………………………………………………………… 221

Step 7: Oven Cure…………………………………………………………………………. 225

After Spraying………………………………………………………………………….. 225

Summary…………………………………………………………………………………………….. 227

Appendix 2: FailZero…………………………………………………………………………………… 229

What’s a FailZero?……………………………………………………………………………….. 229

And the Big Deal for the 1911 Build is…………………………………………………….. 229

There Must be a Downside……………………………………………………………………. 229

Appendix 3: Other Builds with Brief Notes…………………………………………………….. 231

Caspian .357 SIG………………………………………………………………………………….. 231

Frame………………………………………………………………………………………….. 231

Slide…………………………………………………………………………………………….. 231

Barrel(s)……………………………………………………………………………………….. 231

Notes…………………………………………………………………………………………… 233

Colt .45 ACP………………………………………………………………………………………… 233

Frame………………………………………………………………………………………….. 233

Slide…………………………………………………………………………………………….. 233

Barrel…………………………………………………………………………………………… 233

Notes…………………………………………………………………………………………… 233

Colt .45 ACP Series 70 Gold Cup…………………………………………………………….. 235

Frame/Slide/Barrel………………………………………………………………………… 235

Notes…………………………………………………………………………………………… 235

Appendix 4: Miscellany…………………………………………………………………………………. 237

Front Sight Height………………………………………………………………………………… 237

Feed Ramp Polishing……………………………………………………………………………. 237

Melting ………………………………………………………………………………………………. 237

Low Magazine……………………………………………………………………………………… 239

Grip Safety/Hammer Interference…………………………………………………………. 241

Ambidextrous Thumb Safety…………………………………………………………………. 241

Ejector  ………………………………………………………………………………………………. 243

Trigger Over-travel (Stop) Screw Adjustment…………………………………………… 243

Appendix 5: Drop Tests……………………………………………………………………………….. 247

Drake’s Gun Works 1911 Drop Testing Report………………………………………… 247

You can purchase The M1911 Assembly Guide by itself or in the The M1911 Owner’s and Assembly Bundle