For years I looked for an affordable authentic antique punt gun to display in my duck camp cabin. I finally tumbled to the fact that they are scarce and pricy, so I decided to build a replica. Thinking others might like to do the same, I'll document the steps.
Step 1 involved searching the internet and books for examples from which I could create a design that could be simply made with available materials and tools.
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Step 2 was to draw a full-scale plan of the design I settled on.
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In Step 3 I selected and purchased the wood for the stock and forearm. I went with a Douglas fir kiln-dried 4x4, since larger sections were green and would probably crack. The deeper stock end would therefore have to be laminated to the main section.
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In Step 4 I ripped the 4x4 to design width (3"), cut the stock/forearm to length (5'-6"), sawed the crop to the shape of the end of the stock, and laminated it to the main section with glue and screws.
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Step 5 was to saw the top of the main section to the design profile. The stock is very straight and has a shallow drop (1") in order to minimize the depth of the wood section (7").
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In Step 6 I routed out the forearm to receive the barrel (2" ID PVC pipe with 2 3/8" OD). Since I did not have a router or morticing machine, I sawed kerfs and drilled holes in order to make chiseling easier.
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In Step 7, I rounded the edges according to plan using rasps and sandpaper. The fit and finish of punt guns was much less intense than most fowling pieces of the era.
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Step 8 required installing some wood filler where needed and a good sanding before applying a dark walnut stain.
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In Step 9 I installed some authentic antique flintlock hardware (lock, trigger, and trigger guard) that I had purchased on eBay.
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In step 10 I cut the barrel to length (8'-0"), spray painted it flat black, and secured it in the forearm. I am very pleased with the final product and think it will look great mounted on a ceiling beam in the cabin.
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