Ok since I have convinced myself to take a saw to my barrel I want to make sure of the best way to re-crown, I read about the only thing I found on the subject; which was basically nothing more than a champher/bevel/countersink. One suggestion was a good sharp 5/16" bit in a lathe, since I don't have a lathe this could probably be achieved carefully with a hand held drill run at a very slow speed with light pressure and stopping after a couple of turns to inspect. Then follow up with some sandpaper to clean it up a bit.

The one thing I was wondering about though is cleaning up any burrs on the inner edge (bottom of the crown) after drilling, it seems like the bottom of the crown may need to be cleaned up with a sharp knife or sandpaper or something......obviously being careful to not damage the rifling at the start of the crown.

Am I on the right path?

Thanks, Todd

i have a pin vise set, it is basically a handle for dremel bits.
insert a pellet into the crown backwards and push it in a bit.
i use a round grinding bit in medium and fine grit i coat these with coarse and then fine lapping compound.
then lap a crown by hand with equal turns in each direction with the coarse then the fine.
when you like what you have use a cone shape polishing bit to smooth the inside edge of the crown.
when you think you are done clean it up and insert a Q tip spin it once and pull it out, if there is any cotton left at the crown you neen to polish it a bit more with the cone shape bit or a Q tip coated with fine lapping compound.
inpsect your work often i use a jewelers loop as it helps you to see exactly where you need to work and how much work you need to do.

I like it......Excellent explanation. So the diameter of the round dremel grinding bits should be about 5/16? or?

The cone bit is self explanatory, it just needs to touch the edge and not get near the rifling.

That seems like an awful lot of material to remove by hand from scratch but I'll give it a whirl. I'm sure if you're suggesting it, it works.

The pic of my crown on the Storm that I chopped was done with a dremel cone. I lightly touched the bit until there was a bevel, then finished it off with cone polishing tips. It's not a pro job but worked for me countless times and takes me about 5 minutes to do. For plugging the barrel, I usually cut the head off a q-tip and put a drop of oil on the head, then I push it in from the front head first so the stem is just below the opening of the muzzle. When I'm done I use a tweezer and pull the q-tip out, then I run a few patches through to get the rest of the oil and grit the oiled q-tip may have not grabbed.

http://www.airgunone.com/forums/showpost.php?p=726&postcount=10

the instuction i gave you are for an existing crown.
if you are doing a barrel with no crown then you need a bit like in the pic, second from the left and i would use the black speedy handle in the pic for this.
if you are going to use what you have on hand then just go slowly as you can always remove more material but you can't add any so slow is a must with close inspection so you are in control.
the bit second and forth from the left are 3/8 the one in the speedy handle is 1/4 single cut.