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6/2/2005 11:20:52 PM EDT
I have a post-ban FSB that I would like to swap out as it is not longer verboten.  Yes, the original is pinned.  I know its impossible to drill the new FSB to match so I will use the setscrew method.  The problem is the tangent drilled holes in the barrel.

I am thinking of filling these with brass rod and dress it to match the barrel profile and contour, adding flats for the setscrews to bear against.

Would there be any problems with brass rod for filling the slots/holes?  
6/3/2005 6:28:03 AM EDT
[#1]
Should be fine as long as the set screw flats are on the steel of the barrel. With the set screw hitting the brass, it will peen/flair the brass, and make getting the FSB off a real bitch at a later date.

6/3/2005 6:35:17 AM EDT
[#2]
Use a armalite front sight base has clamping screws rather than setscrews, works better. and is stronger to abuse. Not as strong as pinned but better than setscrew.
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