SRD Fall Camporee - Grand Canyon Council

Muskets
SRD Fall Camporee 2015
SRD Fall Camporee
Muskets
Rifled percussion musket, Model 1861 subcontract Bridesburg, with Model 1863 modifications, Indiana
inspected, 1864, .58 cal.
Well it's not an “Exact Replica”, but for the purpose of reenacting and displaying military tactics and procedures
it will work fine. This is only the first cut. It does clean up fairly nice with sanding. So here are some
instructions.
Materials
1inX4in X10ft Pine Common board (makes 2), $5.25 plus tax
Tools
Band saw, Drill with 1in to 1 ¼ in forstner bit. This can be done with a Circular saw or even hand saw but will be
little harder. A combination would even be better because my lines were not very straight with the band saw. A
circular saw would have been great on the long straight lines.
First Cut
After I cut the 10 footer into 2 pieces. I made the first musket using a PDF template supplied by the Camporee
Staff. It turns out to be 48 inches long and the PDF suggests it should be 53 inches long. Muskets tend to be
about as big as the owner, so I stretched it out. I cut out the paper template and taped it to the board.
6/30/2015
Roy Hollis, 602 989 4605, srdscouts.org
Page 1 of 3
Muskets
SRD Fall Camporee 2015
The next part is to cut it out with the band saw or whatever you choose. Can’t help your there, I could barely
help myself. The tough spots are the trigger guard and the hammer.
On the second musket I clamped on the musket template I just created and used a pencil to trace around it.
Well actually I clamped the musket on the board and tried to follow the edge of the musket template, but the
clamps were a nuisance. After that I traced the musket, wiggly lines and all.
From Cutout to Musket
The cutting leaves a very rough edge all around the musket. The edges are also sharp and we want to heavily
round corners. If you have access to a power sander it will greatly speed up the process. Expect to spend a
good hour or more sanding. Start with a coarse grit, 40 to 60. Sand the long edges until smooth. I didn’t worry
about smoothing out the ups and downs, just smoothing the roughness left by the cutting. Ups and downs are
character.
I used the same coarse grit to round the long edges. How much rounding is up to you. I used a power sander to
really round off the top edge to make it a little more like a barrel, but it’s not necessary. If you have access to a
router you can make very quick work of the rounding. Rounding the corners will take a bit more work as you
would like to round the corners quite a bit.
Once you are satisfied that all the sharp edges are gone and the rough spots a fairly smooth, then it’s on to paint
prep. I chose to do a full sanding of all surfaces with 100 grit. Then a final sanding with 220 grit.
On to Paint
Most muskets are not painted, but stained. I chose a dark walnut as walnut is commonly used in rifle stocks. So
I stained the entire surface, my hands, and a pair of pants. I could stop there. Maybe put a coat or two of clear
gloss polyurethane on it for protection.
Instead I decided to paint on a grey colored barrel. I used a latex primer for an initial coat. I added a metal latex
paint over the primer. I did the same for the hammer and the trigger guard. For an added touch of realism I
painted on two metal bands holding on the barrel. Before I arrive at Camporee I plan on adding a couple coats
of polyurethane semi-gloss. Oops, apparently I was 75 years off. It was three bands for the Civil War muskets.
Mine was apparently inherited from my great, great, great . . . grandfather John Hollis that fought bravely in the
revolutionary war for the freedom of the colonies.
So there you have it. If I can do it anyone can!
6/30/2015
Roy Hollis, 602 989 4605, srdscouts.org
Page 2 of 3
Muskets
SRD Fall Camporee 2015
Woodwork Merit Badge
The following shows the parts of this merit badge I would expect to have covered while building the Musket.
Some of the requirements become more discussion because you will likely do this as a group project and buy
materials in bulk. They just need to make a couple of other projects which you might do in the same day or on
another day.
1. Do the following:
a. Explain to your counselor the most likely hazards you may encounter while participating in
woodwork activities, and what you should do to anticipate, help prevent, mitigate, and respond
to these hazards. Explain what precautions you should take to safely use your tools.
b. Show that you know first aid for injuries that could occur while woodworking, including
splinters, scratches, cuts, severe bleeding, and shock. Tell what precautions must be taken to
help prevent loss of eyesight or hearing, and explain why and when it is necessary to use a dust
mask.
c. Earn the Totin' Chip recognition.
2. Do the following: This is a simple addition. Explain why you chose pine (Cheap, ready cut, easy to work
with and stain, etc.) Have some samples of other wooed to show them. Cover part A.
a. Describe how timber is grown, harvested, and milled. Tell how lumber is cured, seasoned,
graded, and sized.
b. Collect and label blocks of six kinds of wood useful in woodworking. Describe the chief qualities
of each. Give the best uses of each.
3. Do the following: Since you would be using tools you will be explaining them and talk about proper use
and clean up.
a. Show the proper care, use, and storage of all working tools and equipment that you own or use
at home or school.
b. Sharpen correctly the cutting edges of two different tools.
4. Using a saw, plane, hammer, brace, and bit, make something useful of wood. Cut parts from lumber
that you have squared and measured from working drawings. You might use powered versions of these
tools, but it’s the same concepts.
5. Create your own carpentry project. List the materials you will need to complete your project, and then
build your project. Keep track of the time you spend and the cost of the materials.
a. This may be more of a discussion of how you went about purchasing the wood and discuss the
other items necessary for the project like sandpaper and paint costs and sourcing.
6. Do any TWO of the following:
a. Make working drawings of a project needing (1) beveled or rounded edges OR curved or incised
cuttings, OR (2) miter, dowel, or mortise and tenon joints. Build this project.
1. Have them add measurements to the PDF template, then do the Musket project.
b. Make a cabinet, box, or something else with a door or lid fastened with inset hinges.
c. Help make and repair wooden toys for underprivileged children OR help carry out a carpentry
service project approved by your counselor for a charitable organization.
7. Talk with a cabinetmaker or carpenter. Find out about the training, apprenticeship, career
opportunities, work conditions, work hours, pay rates, and union organization that woodworking
experts have in your area.
a. This could easily be added in to the project.
6/30/2015
Roy Hollis, 602 989 4605, srdscouts.org
Page 3 of 3