Originally Posted by
RifleGuy
I use a lathe, but a few ideas to help...
1) Drill a hole in a block of wood/aluminum... same diameter as the barrel, then split the block lengthwise with a table saw or band saw. (mark the block so the two pieces can be oriented correctly for clamping later) Use a router or Dremel to cut a relief channel for the rib.
Clamp the block around the barrel, use the block as a guide to create a square end. You can use a belt/disc sander with a guide to keep it square, or just file/sand by hand.
2) Drop it off at my house. I'll mount it in the lathe (or padded vice) square it up, debur the barrel, cold blue the raw metal, then drop it off when done. If you are happy with the result, you owe me one cold Diet Pepsi some time in the future.