Without remorse - Tom Clancy [91]
'You're going to need two of everything,' Kelly said to himself. But first things first. He set the slide on a sturdy jig and used the milling machine first of all to drill two small holes in the top of the slide. -The South Bend machine made an admirably efficient drill, not even a tenth of a turn on the four-handled wheel and the tiny cutting bit lanced through the ordnance steel of the automatic. Kelly repeated the exercise, making a second hole 1.25 inches from the first. Tapping the holes for threads was just as easy, and a screwdriver completed the exercise. That ended the easy part of the day's work and got him used to operating the machine, something he hadn't done in over a year. A final examination of the modified gun slide assured Kelly that he hadn't hurt anything. It was now time for the tricky part.
He didn't have the time or equipment to do a really proper job. He knew how to use a welding set well enough, but lacked the gear to fabricate the special parts needed for the sort of instrument he would have liked to have. To do that would mean going to a small foundry whose artisans might have guessed what he was up to, and that was something he could not risk. He consoled himself with the thought that good enough was good enough, while perfect was always a pain in the ass and often not worth the effort anyway.
First he got a sturdy steel blank, rather like a can, but narrower and with thicker walls. Again he drilled and tapped a hole, this time in the center of the bottom plate, axial with the body of the 'can,' as he already thought of it. The hole was .60 inches in diameter, something he had already checked with a pair of calipers. There were seven similar blanks, but of lesser outside diameter. These he cut off to a length of three quarters of an inch before drilling holes in their bottoms. These new holes were .24 inches, and the shapes he ended up with were like small cups with holes in the bottom, or maybe diminutive flowerpots with vertical sides, he thought with a smile. Each of these was a 'baffle.' He tried to slide the baffles into the 'can,' but they were too wide. That earned Kelly a grumble at himself. Each baffle had to go on his lathe. This he did, trimming down the outside of each to a shiny, uniform diameter exactly one millimeter less than that of the inside of the can, a lengthy operation that had him swearing at himself for the fifty minutes it required. Finished, finally, he rewarded himself with a cold Coke before sliding the baffles inside the can. Agreeably, they all fit snugly enough that they didn't rattle, but loosely enough that they slid out with only a shake or two. Good. He dumped them out and next machined a cover cap for the can, which had to be threaded as well. Finished with that task, he first screwed it into place with the baffles out, and then with the baffles in, congratulating himself for the tight fit of all the parts - before he realized that he hadn't cut a hole in the cover plate, which he had to do next, again with the milling machine. This hole was a scant .23 inches in diameter, but when he was done he could see straight through the entire assembly. At least he'd managed to drill everything straight.
Next came the important part. Kelly took his time setting up the machine, checking the arrangements no less than five times before doing the last tapping operation with one pull on the operating handle - that after a long breath. This was something he'd observed a few times but never actually done himself, and though he was pretty good with tools, he was a retired bosun, not a machinist's mate. Finished, he dismounted the barrel and reassembled the pistol, heading outside with a box of .22 Long Rifle ammunition.
Kelly had never been intimidated by the large, heavy Colt automatic, but the cost of .45 ACP was far higher than that of .22 rimfire cartridges, and so the previous year he'd purchased a conversion kit allowing the lighter rounds to be fired through the pistol.