Abstract:

A method for manufacturing double barrel shotgun barrels, including the steps of providing an
elongated metal stock material having a first end and a second end, forming two index holes in
both the first end and the second end of the material, forming a first and second bore hole
through the material, and then profiling the material into a desired gun barrel profile. 16. Double
barrel shotgun barrels formed from a single piece of elongated solid metal stock material
according to the process of the invention are also taught.

Claims:
1-16. (canceled)

17. A method for manufacturing a gun barrel from an elongated solid metal stock material, the
method comprising:forming on the elongated solid metal stock at least one set of opposed index
markers at both a first end and a second end of the solid metal stock material wherein each set of
index markers is offset with respect to each other set of index markers;forming on the elongated
solid metal stock at least one external guide along a longitudinal length of the solid metal stock
material wherein each external guide is spaced from each other external guide at a relative angle;
andboring at least one projectile hole through the solid metal stock material, said hole being
defined by the at least one set of index markers and at the at least one external guide.

18. The method of claim 17 further comprising profiling the metal stock material subsequent to
said boring using machining equipment into a gun barrel.

19. The method of claim 17 wherein each external guide is associated with one index market set.

20. The method of claim 17 wherein said solid metal stock material is machine profiled using
machining equipment selected from Computer Numerical Controlled machines (CNC) with
Computer Assisted Drawings (CAD) converted to tool paths, and combinations thereof.

21. The method of claim 17 wherein said solid metal stock material is machine profiled and
polished using Electrical Discharge Machining (EDM) equipment.

22. The method of claim 17 wherein the relative angle between a first external guide and a
second external guide represents an angle of convergence between a first projectile hole and a
second projectile hole.

23. The method of claim 22 wherein the angle of convergence between the first projectile hole
and the second projectile hole is from about 0.35.degree. to about 0.4.degree..

24. The method of claim 22 and further comprising the steps of:positioning said solid metal stock
material in a fixture of a boring apparatus, the fixture having a means for receiving said first
external guide;positioning said first external guide in said fixture at the angle of convergence
with respect to said boring apparatus;boring the first projectile hole through the solid metal stock
material;removing the solid metal stock material from the fixture;positioning said second
external guide in said fixture at the angle of convergence with respect to said first projectile hole
and said boring apparatus; andthenboring the second projectile hole through the solid metal stock
material.

25. The method of claim 17 and further comprising the steps of drilling cooling fluid circulation
holes adjacent the first end and the second end of the solid metal stock material.

26. A gun barrel made from an elongated solid metal stock material using a gun barrel
manufacturing process, the process comprising:forming on the elongated solid metal stock at
least one set of opposed index markers at both a first end and a second end of the solid metal
stock material wherein each set of index markers is offset with respect to each other set of index
markers;forming on the elongated solid metal stock at least one external guide along a
longitudinal length of the solid metal stock material wherein each external guide is spaced from
each other external guide at a relative angle; andboring at least one projectile hole through the
solid metal stock material, said hole being defined by the at least one set of index markers and at
the at least one external guide.

Description:
BACKGROUND OF THE INVENTION

[0001]1. Field of the Invention

[0002]This invention relates generally to a process for metal working to produce double barrel
shotgun barrels, and, more particularly it relates to a process for manufacturing over/under and
side-by-side shotgun barrels from a single piece metal stock, and also to the resulting monolithic
shotgun barrels so produced.

[0003]2. Description of the Prior Art

[0004]Double barrel shotguns are long known in the art. There are two basic types of double
barrel shotguns being manufactured today. A first type of double barrel shotgun is commonly
referred to as a "Chopper Lump" (English terminology) or a "Demibloc (Italian terminology)"
barrel, and will herein be referred to as "Demibloc". Demibloc barrels are formed from two metal
tubes or single barrels, preferably of steel, that are of a length sufficient to form a shotgun. As a
first significant step, the two metal tubes soldered together to form a roughly joined double
barrel. The resulting double barrel is then filed, machined and otherwise worked in multiple steps
using the skills and labor of multiple trades and crafts people. For example, as a first step a
"Joiner" joins the two individual metal tubes and then solders them together along substantially
their entire lengths. An "Actioner" fits and files the rough barrel to fit and match a separate
action or firing mechanism to which the double barrel is to be attached. A "Striker" files the
surfaces of the joined rough double barrel pieces to a desired finish. A "Straightener" straightens
or regulates the joined barrels and also adjusts or bends the individual barrels by eye into a
relative position to allow each barrel to shoot a projectile straight and also into a desired
converging shot pattern at a given distance. A "Rib installer" solders the top sighting rib onto the
combined double barrel tube, and also solders side ribs on either side of the tubes between the
two barrels to secure them in the desired relative position. Finally, a "Bluer" treats the combined
double barrel to produce the desired oxidized blue-black coating onto the double barrel.

[0005]The second type of double barrel shotgun is commonly referred to as a "Monobloc"

(Italian term). A Monobloc double barrel shotgun consists of an action block of metal, preferably
steel, fitted to the action or firing mechanism of the shotgun. The Monobloc is preformed to
carry at least two receiving holes designed to accept a pair of separate barrel tubes. Each separate
tube is then set into and soldered to a receiving hole of the action block so that each protrudes
from the action block, and is of a length sufficient to be formed into a shotgun. The two tubes are
then held in position with wire or by a fixture and are then roughly tacked together along their
entire lengths with solder. Then, the joined barrels are straightened or "Regulated" by hand into a
relative position to allow each barrel to shoot a projectile straight and also into a desired
converging or overlapping shot pattern at a prescribed distance. Next, the barrels are sent to a
"Rib installer" to solder the top sighting rib and side ribs between the barrels that hold the tubes
in place. The rough barrels are then sent to a "Striker" or "Finisher" to finish the surfaces of the
barrels by filing and sanding. Finally, the barrels are sent to "Bluer" for bluing and final finish.

[0006]In addition, double barrel shotgun barrels are formed by the Demibloc and by the
Monobloc process in over/under (O/U) and side by side (S/S) shotgun barrels

[0007]It can therefore be seen, that the process of making a double barrel, whether by the
Demibloc or the Monobloc process consists of a large number steps performed by many crafts an
trades people, and, as a practical matter requires a great deal of time, say up to two and one half
years to complete.

[0008]Accordingly, there exists a need for a process for manufacturing double barrel shotgun
barrel systems which allows what have heretofore been many dissimilar trades to perform
manufacturing and machining and finishing steps quickly, efficiently and in harmony in order to
arrive at a finished double barrel shotgun barrel within a required specification. Additionally, a
need exists for a process for manufacturing shotgun barrels which is quick and inexpensive and
easy to replicate with precision. Furthermore, there exists a need for a process for manufacturing
double barrel over/under and/or side by side shotgun barrels which allow a broad range of
different types of barrels to be produced using substantially the same single piece of metal stock
and material blank. There is a further need to precisely produce such double barrel over/under
and/or side by side shotgun barrels quickly and without the use of the labor of multiple trades or
craftsmen.

SUMMARY OF THE INVENTION

[0009]The present invention teaches methods for manufacturing double barrel shotgun barrels. In
one embodiment the method comprises providing an elongated metal stock material of a given
length and of sufficient height and width to be formed into a double barrel shotgun, the metal
stock material having a first end and a second end. So long as the metal stock material meets
those size requirements, it may be round, or square, or rectilinear or irregular in cross section, the
desired starting cross section being easily milled or otherwise formed on the metal stock
material. For purposes of simplicity it will be assumed that the metal stock material is round, or
cylindrical or rectilinear in cross-section. As a first significant step in creating the double barrel
of the present invention, two separate and spaced apart index markers are formed at both the first
end of the metal stock material and at the second end of the metal stock material. The second
index marker formed in the second end of the metal stock material is opposed to and aligned
precisely linearly with the first index marker formed in the first end of the metal stock material
longitudinally through the length of the metal stock material. The second index marker formed in
the second end of the metal stock material is also opposed to and aligned linearly with the first
index marker formed in the first end of the metal stock material longitudinally through the length
of the metal stock material. Each pair of opposed first and second index markers serve to define
what will be the centers of to-be-bored holes. In addition, and as is explained below, the index
markers allow the metal stock material to be moved from one machine to another during various
steps of the process of the present invention.

[0010]A first substantially straight guide element is then formed linearly along one surface of the
external longitudinal length of the metal stock material. The first guide marker runs in a
substantially straight line between the first end of the metal stock material and the second end of
the metal stock material. A second guide marker is then formed linearly along the external
longitudinal length of the metal stock material, and runs in a substantially straight line between
the first end of the metal stock material and the second end of the metal stock material. However,
the second external guide marker is spaced apart from and on a surface opposed to the first guide
marker, and as explained and greater detailed below, is angled relative to the first external guide
marker at what will be the angle of convergence of the to-be-formed bore holes. Then, using the
first and second pairs of index markers, the first and second holes to be bored are established A
first bore hole is formed linearly through the length of the metal stock material, the first bore
hole being aligned with and guided by the first guide marker. Then, the second pair of index
markers are used to establish the location of the second bore hole to be formed linearly through
the length of the metal stock material, the second bore hole being aligned with and guided by the
angle of the second guide marker, and therefore at the predetermined angle of convergence at a
given distance from the end of the barrels. In practice, the angle of convergence between the first
projectile hole and the second projectile hole is usually in the range of about 0.35° and about
0.4°. All of these steps are achieved with a minimum of handling; require no skilled trades or
craftsmen. Then, the double barrel thus formed may be profiled and finished with a minimum of
handling and without requiring skilled trades or crafts people.

[0011]As used with the present invention, the "index markers" may be holes or raised points, or
any other form of index marker. Similarly, the "guide element" may be grooves, rails, or any
other form of guide element.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012]FIG. 1 is an exploded perspective view illustrating a state-of-the-art stock and trigger

mechanism in relation to a finished over/under double barrel shotgun barrel constructed in
accordance with the process of the present invention;

[0013]FIG. 2 is a perspective view illustrating a state-of-the-art stock and trigger mechanism

shown joined to a finished side-by-side double barrel shotgun barrel constructed in accordance
with the process of the present invention;

[0014]FIG. 3 is an interrupted side elevational view illustrating a typical solid cylindrical metal
stock material before it has undergone any of the steps of the method of the present invention to
produce a double barrel shotgun barrel;

[0015]FIG. 4 is a right end elevational view of the cylindrical metal stock material of FIG. 3
before it has undergone any of the steps of the method of the present invention, the left end view
being a mirror image thereof;

[0016]FIG. 5 is an elevational side view of the cylindrical metal stock material of FIG. 3,
partially in section at its left and right ends to illustrate a pair of index holes at its left and right
ends;

[0017]FIG. 6 is a right end elevational view of the cylindrical metal stock material of FIG. 5
illustrating the pair of index holes, the left end view being a mirror image thereof;

[0018]FIG. 7 is an elevational sectional side view of the metal stock material of FIG. 5, and now
further processed and illustrating first and second converging guide grooves formed in the outer
surface of the stock material;

[0019]FIG. 8 is a right end elevational view of the cylindrical metal stock material of FIG. 7
illustrating the first and second converging guide grooves as well as the pair of index holes, the
right end view being substantially a mirror image thereof, but with the guide grooves slightly
closer to one another;

[0020]FIG. 9 is an elevational sectional side view of the metal stock material of FIG. 7, but now
further processed and illustrating first and second bore holes formed through the stock material,
with fixture holes shown formed at the left end of both the first and second bore holes, but at
only the first bore hole on the right end, and further illustrating holes drilled into the material for
circulation of coolant;

[0021]FIG. 10 is a left side view of the cylindrical metal stock material of FIG. 9, the left end
view being similar thereto, but for the absence of a fixture hole in the second bore hole on the
right end;

[0022]FIG. 11 is an elevational side view of the material of FIG. 9, but now further processed
and illustrating, but for the left and right blocks of stock material, the now nearly complete
profiled over/under double barrel shotgun barrel constructed in accordance with the process of
the present invention; and

[0023]FIG. 12 is an elevational side view of the material of FIG. 11, but now further processed
and illustrating, the left and right blocks of stock material removed, to form a now complete
over/under double barrel shotgun barrel, as shown in perspective in FIG. 1, and constructed in
accordance with the process of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0024]Referring first to FIG. 1, illustrates a perspective view illustrating a complete double

barrel shotgun 10A having a side by side (S/S) double barrel 12A constructed in accordance with
the process of the present invention. FIG. 2 provides an exploded perspective view illustrating an
over/under (O/U) double barrel shotgun 10 including a state-of-the-art butt stock 14 having a
trigger mechanism 16 and a forend 18, in relation to an O/U double barrel 12 constructed in
accordance with the process of the present invention, as detailed below. Illustrated on the O/U
double barrel 12 are a standard joining or side rib 22 between the two barrels, a top rib 24, a false
rib 26 and a forend latch 28 carried by and produced as parts of a finished over/under double
barrel shotgun barrel 12 constructed in accordance with the process of the present invention.
Like parts on O/U shotgun 10 and shotgun S/S 10A have like numbers.

[0025]The process for manufacturing over/under (O/U) 12 or side by side (S/S) 12A shotgun
barrels of the present invention begins with obtaining a single piece of metal stock material 32,
as shown in FIGS. 3 and 4. In the preferred practice of the present invention, the metal stock
material 32 is a solid piece of metal, preferably of art known gun barrel grade steel. In the
embodiment shown in FIGS. 3 and 4, stock material 32 is substantially circular in cross-section,
although square or rectangular or other shaped stock material 32 may be used in the method of
the present invention. In addition, it is within the scope and teaching of the method of the present
invention to produce shotgun barrels 12 or 12A from other metal stock materials having other
workable cross-sections. In any event, the starting metal stock material 32 is generally solid and
elongated and has a first end 34 and a second end 36. For ease of operation and handling, both
first end 34 and second end 36 of the solid metal stock material 32 are formed or cut flat and
substantially orthogonal to the linear length of the stock material 32, and both first end 34 and
second end 36 are formed substantially parallel to one another. Stock material 32 is of a length,
height and width sufficient to be formed into and produce a double barrel O/U 12 or S/S 12A
shotgun barrel.

[0026]The process of the present invention for manufacturing double barrel O/U or S/S shotgun
barrels 12 or 12A according to the present invention is comprised of several steps, as well as
optional steps. The first step, after obtaining an appropriate metal stock material 32, is
determining the ultimate angle of convergence of the first and second two to-be-bored projectile
holes 42 and 44, respectively (see FIGS. 9 and 10). As discussed below, the angle of
convergence of projectile holes 42 and 44 is determined by the laws of ballistics and physics.
The production of the angle of convergence for projectile holes 42 and 44 begins with forming
pairs of index markers 46 and 48 on the first and second ends 34 and 36 of metal stock material
32.

[0027]Now, in order to produce and replicate O/U or S/S double barrel barrels accurately and
consistently, two precisely located and spaced apart index markers 46 and 48 are formed at the
first end 34 of the solid metal stock material 32, and two precisely located and spaced apart
matching index markers 46 and 48 are also formed at the second end 36 of the solid metal stock
material 32. In preferred embodiments each pair of two index markers are a pair of spaced apart
holes 46 and 48, formed, for example, by drilling into the first end 36 and a second end 46 and
48 of solid substantially cylindrical metal stock material 32. The first pair of index holes 46 and
48 formed in the first end 34 of the metal stock material 32 are preferably aligned linearly with
the second pair of index holes 46 and 48 formed in the second end 36 of the metal stock material
32. Each pair of index holes 46 and 48 are aligned longitudinally through the length of the metal
stock material 32 with the opposed pair of index holes 46 and 48. In the preferred practice of the
present invention, the two index markers 46 and 48 at the first end 34 and the two index markers
46 and 48 at the second end 36 of solid stock material 32 are located between about 2.0 inches
apart and about 2.5 inches apart. While the index markers 46 and 48 are herein noted to be holes,
and specifically to be drilled holes, the index markers may be formed in any other manner, for
example as projections, and by any other method.

[0028]Next, based on the locations of index markers 46 and 48, the exterior of metal stock
material 32 is then profiled, using equipment and methods as detailed below, including the
formation of accurately positioned converging external guides 52 and 54. Converging external
guides 52 and 54 are located relative to one another at what will be the angle of convergence of
the first and second to-be-bored projectile holes 42 and 44. As shown in FIGS. 7 and 8, such
external guides are preferably in the form of straight linear grooves 52 and 54 for use in guiding
the boring of the converging bore holes 42 and 44. A pair of first straight guide grooves 52 are
formed linearly, but opposed to one another along both sides of the external longitudinal length
of the metal stock material 32. The first guide groove elements 52 run in a substantially straight
line between the first end 34 and second end 36 of metal stock material 42. A second pair of
guide groove elements 54 are then formed linearly, but also opposed to one another along both
sides of the external longitudinal length of the metal stock material 32. along the external
longitudinal length of the metal stock material, and also runs in a substantially straight line
between the first end 34 of the metal stock material 32 and the second end 36 of the metal stock
material 32. However, the second pair of external guide grooves elements 54 is spaced apart
from, and are angled relative to the first pair of external guide groove elements 52. The angle of
the second pair of external guide grooves 54 will serve to guide the angle of convergence of the
to-be-formed bore holes 42 and 44.

[0029]Then, as illustrated in FIGS. 9 and 10, two small, say 1/4 inch circulation holes 72 are
drilled and tapped, say about 2.5 inches to about 3 inches from the ends 34 and 36 of the metal
stock material 32, and into the first and second projectile bores 42 and 44. The circulation holes
72 allow for circulation of coolant by art known means during the profiling and Electrical
Discharge Machining (EDM) process as described below. The foregoing not withstanding,
circulation holes 72 and the step of circulating coolant can be omitted, if desired.

[0030]Then, after the location and setup of index markers 46 and 48 at ends 34 and 36 of solid
metal stock material 32 is used to produce external guide groove elements 52 and 54 for either
O/U 12 or S/S 12A shotgun barrels, external guide groove elements 52 having precise locations
and angles of convergence are used to locate two to-be-bored projectile bore holes 42 and 44 that
provide the desired overlap pattern that at a given distance. This is accomplished using the first
pair of external guide groove elements 52 for alignment, a first bore hole 42 is formed linearly
through the longitudinal length of the metal stock material 32, first bore hole 42 is formed using
any suitable boring system. Then, metal stock material 32 is moved and placed into a second
alignment with the boring system using second alignment guide groove elements 54, and second
bore hole 44 is then formed linearly through the longitudinal length of the metal stock material
32 also using any suitable boring system, but at the predetermine angle of convergence with first
bore hole 42, as shown in FIGS. 9 and 10. It is within the teaching and tolerances of the present
invention to produce second bore hole 44 before first bore hole 42. Thus, the two to-be-bored
converging holes 42 and 44 are precisely located and bored based on the positions of the four
index holes 46 and 48 holes and the external guide groves 52 and 54. In the alternative, but not
as simply, index holes 46 and 48 can be used, without forming external guide groove elements
52 and 54 to align a moveable machining table or other device to establish an offset angle
between bore holes 42 and 54, for example with Computer Assisted Drawings (CAD) converted
to tool paths equipment, or print specification.

[0031]The method of actually forming bore holes 42 and 44 in stock material 32 is not critical to
the practice of the present invention. However, what ever type of bore hole forming system is
used, converging external guides 52 and 54 will preferably be used to select and guide the angle
of convergence between bore holes 42 and 44. For example, since the early eighteenth century a
fixed, non-moveable single axis hand turned boring or drilling machine has been used to produce
bore holes, and may be used to produce bore holes 42 and 44 in the practice of the present
invention. This can be accomplished by cutting two longitudinal grooves like 52 and 54 in the
surface of stock material 32, which grooves represent the desired convergent directions of bore
holes 42 and 44. However, in the preferred process of the present invention, state-of-the-art
automated power boring machines such as Computer Numerical Controlled (CNC) machines are
used with converging external guides 52 and 54 to select and guide the angle of convergence
between bore holes 42 and 44. As an important step in the process of the present invention, in
order to accurately replicate bore holes from stock material 32 to stock material 32, one must
mechanically establish the location of those bore hole centers. In the preferred practice of the
present invention, those bore hole centers are locatable from index marker elements 46 and 48
which allow each piece of stock material 32 to be moved and repositioned on any boring
machine, as the marker elements 46 and 48 serve as reference indexes that identify the correct
location of the to-be-bored projectile holes 42 and 44 within the stock material 32, regardless of
what type of boring machine was originally used. Once such converging external guides 52 and
54 are alternately placed on a machining table having a compatible locating element for aligning
the boring element, and fixed into position, the boring machine hole line will be represented by
the line of the guides 52 and 54. Therefore, in practice, when a first hole, say 42 is completed
using external guides 52, the stock material 32 can then be placed in the second external guides
54, and the boring machine aligned to external guides 54, and bore hole 44 established with the
desired angle of convergence. In each instance, the alignment of stock material 32 is established
on the table and in the fixture by reference to index markers 46 and 48.

[0032]In the alternative, where the boring machine has very accurate moveable tables for
positioning stock material 32, and where the centers of projectile holes 42 and 44 are locatable
from index marker elements 46 and 48, the stock material 32 can be moved and positioned with
respect to the boring tools so that and projectile bore holes 42 and 44 can be produced without
reference to or use of converging external guides 52 and 54. Subsequently, the surface of stock
material 32, as shown in FIGS. 9 and 10, is then profiled and machine finished to the profile
shown in FIG. 11, but without removing unfinished end portions 62 and 64. Such profiling and
finishing is easily completed using state-of-the-art CAD and other state-of-the-art machining
tools, such as CNC machines and EDM processing. If desired or required, during the profiling
and EDM machining processes, circulation holes 72 may be used to circulate coolant within
bored projectile holes 42 and 44.

[0033]Finally, as shown in FIG. 12, end portions 62 and 64 are removed, for example by cutting
them off to a specified length, and barrel 12 is completed to produce a now substantially
complete O/U double barrel shotgun barrel 12 constructed in accordance with the process of the
present invention. Of course, further finishing or customizing of the surfaces, and bluing or other
final custom finish may be provided by time consuming art known means. It will be seen that
barrel 12 as shown in FIG. 12 is the same as that shown in FIG. 12. In the practice of the method
of the present invention the bored stock material is preferably transferred to a state-of-the-art
lathe, not shown, for profiling. The holding fixture, also not shown, of the lathe is keyed to the
two pairs of index holes 46 and 48 with matching pegs. The index holes 46 and 48 allow the true
center of each of the to-be-formed converging bore holes 42 and 44 inside of the metal stock
material 32 to be defined. Measurements from the center of bore holes 42 and 44 allows proper
finish machining and profiling of the finished product, as shown in FIGS. 11 and 12. Such
finishing of the bored gun barrel 12 or 12A is produced by extensive milling, preferably followed
by electric discharge machining (EDM). In the EDM finishing step a mating pair of female
electrode replicas, not shown, of the profile of the final external barrel are first made. The rough
finished barrel is then compressed between the two electrodes and EDM machined until a highly
finished external profile is attained. The end result is a barrel 12 or 12A that, in production, has
required little to no hands on specialty human labor.

[0034]It is apparent, that by adjusting the orientation of the system by 90° in several of the steps
discussed above, that a S/S double barrel shotgun barrel 12A can be produced. It should be noted
that side and top ribs 22 and 24 are produced with and integral to the finished double barrel
products.

[0035]In any event, it is clear that in the practice of the method of the present invention, the
monolithic O/U or S/S double barrels are not made from a composite of two tubes or single
barrels that are joined together, for example by soldering, to make a joined, but not monolithic
double barrel. Nor is it necessary for single barrels to be joined together and then bent relative to
one another during their joining by eye reckoning into position to a desired angle of
convergence, as in the prior art Demibloc and Monobloc processes. Rather, since the starting
stock material 32 for production of O/U or S/S double barrels is solid elongated metal stock
material in which the two bore holes 42 and 44 are accurately formed having the desired angle of
convergence within the solid metal stock material 32, and remains as a continuously joined
monolith that is neither amenable to or capable of having its bore holes 42 and 44 bent relative to
one another to adjust their angle of convergence. In addition, the bore holes 42 and 44 formed
within the solid metal stock material 32 produced using the method of the present invention react
differently to the harmonics waves of flexation that are generated during firing of a projectile
through bore holes 42 and 44, as compared to the flexation produced by the counterpart state-of-
the-art joined double barrel produced by conventional Demibloc and Monobloc methods of
manufacture, and therefore the angles of convergence that have been determined for use with the
prior art joined systems are not applicable to the angles of convergence required for the double
barrel shotgun barrels produced by the method of the present invention. It is therefore understood
that the determination of the angle of convergence of the two bore holes 42 and 44 produced by
the method of the present invention is a key element to producing even and overlaying shot
patterns at any given distance. Because of the above noted differences in the harmonics waves of
flexation that are generated during firing of projectiles from shotgun barrels produced by the
method of the present invention, the selection of the angle of convergence for an O/U or S/S
barrel formed from solid metal stock material is also different from those known and used for
double barrels produced by prior art Chopper Lump and Demibloc.

[0036]By using the indexing holes and other steps and techniques described herein, the shotgun
barrels produced by the method of the present invention can be reproduced with precision for
each to-be-produced shotgun barrel, thus making the shotgun barrels interchangeable from
shotgun to shotgun. For the most part, double barrel shotgun barrels produced by prior art
methods have required semi-precise machining for each individual shotgun system and further
finished by hand, and are not interchangeable from shotgun to shotgun. Similarly, the center to
center bored holes 42 and 44 can be produced in sizes that are compatible with a large number of
double barrel shotgun barrels in use today of a like gauge. It will be appreciated that the double
barrel gun barrels can be finished to assume different forms in accordance to the needs of a
manufacturer or gunmaker. A particular profile of a gunmaker's barrel can be produced in either
the O/U or S/S type barrels of the present invention.

[0037]Thus, the process of the present invention which produces a solid monolithic barrel with
little or no hands on skilled labor replaces the Demibloc barrel manufacturing procedures that
require multiple trades and a great deal of time to complete. By comparison, the process of
making a solid block barrel according to the method of the present invention to produce a single
complete one piece solid unit is simple and fast. For example, in the current practice, a Demibloc
barrel which is made using a number of Tradesmen takes approximately two and one half years
to complete. By comparison, the double barrel of the present invention can be reproducibly
manufactured and completely finished in about eight to about 24 hours, depending on the
sophistication of the machines used. However, in producing the completed form shown at FIGS.
1, 2 and 12, the process of the present invention eliminates substantially all of the trade crafts
required in the process of making a Demibloc barrel. Further, by selection of premium steel, such
as Vacuum Arc Remelt Steel, rarely used because of its difficult machining properties, it can
reduce the explosive bursting defects of barrels made of lesser material, thereby potentially
saving injuries, life and property. Further, the solid barrel process of the present invention
eliminates the issue of solder joints coming loose with use or age. Since side and top ribs 22 and
24 are integral to the finished product, it also prevents them from delaminating, and the soldered
joints from separating, as in a Demibloc system, which are common prior art problems. The
monolithic barrel produced by the process of the present invention eliminates all of these
failures, while at the same time improving barrel burst safety by as much as 700% depending on
the metal material selected. Stated simply, seven stages and crafts of prior art Demibloc barrel
manufacturing are eliminated by using the solid barrel process of the present invention, while the
cost to make the barrel remains about the same or less, and is much quicker and totally
reproducible. Furthermore, the double barrel shotgun barrels so produced have close and
reproducible tolerances, can be made from one solid piece of steel and can be made to resemble a
Monobloc piece design, and can be made as a solid barrel or designed in part to be soldered into
an existing state-of-the-art action block, thereby producing a new two piece solid barrel design.
[0038]In addition, side by side barrels, single barrels, pistol barrels, rifle barrels, and double rifle
barrels can also be produced using the process of the present application.

[0039]The foregoing exemplary descriptions and the illustrative preferred embodiments of the
present invention have been explained in the drawings and described in detail, with varying
modifications and alternative embodiments being taught. While the invention has been so shown,
described and illustrated, it should be understood by those skilled in the art that equivalent
changes in form and detail may be made therein without departing from the true spirit and scope
of the invention, and that the scope of the present invention is to be limited only to the claims
except as precluded by the prior art. Moreover, the invention as disclosed herein may be suitably
practiced in the absence of the specific elements which are disclosed herein.

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