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August 2nd, 2014

How Brux Barrels are Made — Precision Start to Finish

Brux Barrels, based in Lodi, Wisconsin, has earned a reputation for producing great-shooting tubes. Brux-made barrels have won their fair share of matches, and set some notable records in the process. Last year, Rodney Wagner shot the smallest five-shot, 600-yard group (.0349″) in the history of rifle competition, using a Brux barrel chambered for the 6mm Dasher.

Folks often ask us why Brux barrels shoot so well. “What’s the secret?” they ask. We can only answer with what Brux explains on its own website: “To make a cut-rifled barrel you have to start off with the proper ingredients: the best steel available, skill, and experience. Since there are really only two main suppliers of barrel-quality steel, the skill and experience is what really makes a barrel maker stand out.” Here is how Brux’s co-owners, Norman Brux and Ken Liebetrau, explain all the procedures involved in making a Brux cut-rifled barrel:

Brux Barrel-Making Process, Start to Finish

We start out with either 4150 chrome-moly or 416R stainless steel double stress-relieved bar stock. The bar stock starts out at 1-9/32″ in diameter and 20-24 feet long so we cut it to length.

Step two is to rough-contour the outside of the barrel blank in a lathe.

Thirdly, the blank gets mounted into a Barnes gun drill. The cutter bit has holes through which oil or coolant is injected under pressure to allow the evacuation of chips formed during the cutting process. This is called “oil-through” or “coolant-through”. Without this, you wouldn’t want to even attempt drilling a hole 30” long and under ¼” in diameter. The combination of a 3600rpm and good flushing allows us to drill a beautifully straight and centered hole .005” under “land” diameter at a rate of 1” per minute.

Clean the barrel.

Next the blank is sent back to the lathe to machine the finished contour of the outside.

Clean the barrel again.

Now, the blank is sent on to the Pratt & Whitney reamer in which an “oil through” reaming tool is used to cut away the extra .005” left in the drilling process. The reamer makes an extremely accurate bore size and after it is finished the bore will have a better surface finish and will be at the proper “land” diameter.

Clean the barrel again.

In the sixth step we hand lap each barrel to remove any slight tool marks that may have been left by the reamer and inspect every one with a bore scope. If the barrel doesn’t meet our standards for surface finish and tolerance it doesn’t get any further.

Clean the barrel again.

The barrels then go onto the rifling machine which is responsible for cutting the all so familiar grooves in the bore. A caliber/land configuration-specific rifling head is used to progressively shave away small amounts of steel to form the rifling grooves. This is accomplished by simultaneously pulling the rifling head through the reamed blank as the blank is spun at a controlled rate. After each cut, the blank is rotated 90 degrees (for a four-land configuration) and after one full rotation (360 degrees) the rifling head is slightly raised to shave off the next bit of material. This process is repeated until we reach groove diameter.

Clean the barrel again.

Lastly, the barrel is hand-lapped again (to ensure a smooth bore), and a final inspection is performed with the bore scope.

The barrel is cleaned one last time, wrapped, packed, and shipped to [the customer].

Anyone reading this detailed description of the Brux barrel-making process will doubtless come away with a new appreciation for the time, effort, and dedication required to produce a premium match-grade cut-rifled barrel. Obviously, there are no easy shortcuts and great attention to detail is required each step of the way. As shooters we’re lucky that we have barrel-makers so dedicated to their craft.

Credit James Mock for steering us to this Barrel Making 101 feature on the Brux website.

Permalink - Articles, Gunsmithing 8 Comments »
October 29th, 2013

Extreme Long-Range Accuracy — Making the Mile Shot

As a member of the World Champion Team USA F/TR squad, Paul Phillips regularly competes (and wins) at 1000 yards. Paul is also a long-range hunter. Here’s his story about developing his ultimate long-range hunting rifle. Chambered for the .338 Lapua Magnum, this rig is accurate out to 1800 yards.

The Long-Range Challenge By Paul Phillips
Being an avid big game rifle hunter, my goal was to build the most accurate long-range hunting rifle possible that would still be light enough to carry. My thought was to use the same type of high-quality components as what I used on my US F/TR Team Rifle, except in a bigger caliber — a caliber that would have plenty of knock-down power at very long ranges. After extensive research, including both ballistic data analysis, as well as discussion with top gunsmiths and champion long-range shooters, I chose the .338 Lapua Magnum. My past experience from being a member of a USMC Scout Sniper Platoon and a shooting member of two World Champion U.S. F-Class F/TR teams, I knew that this rifle was more than capable of performing the task. After establishing that the rifle had half-MOA accuracy at 600 yards, we wanted to see how far the rifle could maintain sub-MOA accuracy, to see what the cartridge and rifle could achieve. Could this gun shoot sub-MOA at a mile? That was our challenge.

Paul Phillips .338 Lapua Magnum rifle one mile Brux Barrel McMillan A5 stock

Rifle Components and Gunsmithing
My rifle was built on a Stiller Tac-338 single-shot action. It has a 30″, 1:10″-twist Brux barrel, a McMillan A-5 stock with Magnum fill, a Sinclair Bipod, and a Remington X-Mark trigger set at two pounds. The rifle wears a Nightforce NXS 8-32x56mm scope in Nightforce rings on a +40 MOA rail. I chose David Tooley to install the barrel, custom brake, apply a Cerakote dark earth finish and bed the stock. After speaking with Mr. Tooley in great length, I chose his no-neck-turn match .338 Lapua chamber specifically designed for the 300 grain Berger Bullet. This rifle weighs 17 pounds and, with the muzzle brake, it recoils like a standard .308 Winchester.

Paul Phillips .338 Lapua Magnum rifle one mile Brux Barrel McMillan A5 stock

Load Development and Accuracy Testing
I used the 600-yard range at the Midland County Sportsman’s Club. If I was going to have any chance of hitting small targets at a mile, I would need to find a load that could produce half-minute (0.5 MOA) or better accuracy. I found an accurate load that gave me consistent half-minute groups that chronographed at 2825 FPS. My load consisted of Lapua brass, Federal 215M Primer, Alliant Reloder 25, and Berger 300gr Hybrid OTM bullet. With the Berger 300-grainer’s listed 0.419 G7 BC, this load would be good enough to reach 1880 yards before going subsonic. This load’s calculated energy at one mile is 960 ft/pounds. This is similar to a .44 magnum pistol round at point-blank range.

Paul Phillips .338 Lapua Magnum rifle one mile Brux Barrel McMillan A5 stock

With my +40 MOA scope rail, my 100-yard zero ended up with the elevation at the bottom of the tube and the windage just 2 MOA left of center. This left a full 65 Minutes of Elevation — enough to get out to 1800 yards. This gave me the capability to aim and shoot from 100 yards to 1800 yards with a projectile that is still supersonic at 1800.

Hitting a 10″ Balloon at One Mile
For a one-mile target, I chose a balloon inflated to 10″ in diameter. The balloon would be a challenging, reactive target that would show up well on video. I teamed up with a fellow long-range shooter, John Droelle and friend Justin Fargo to attempt this feat. Using my known 600-yard Zero, my ballistics program showed my come-up for 1783 yards to be 53 MOA. After two sighters that measured 4 inches apart, I adjusted up one minute from my spotter shot and nailed my 10″ balloon at one mile. This video was recorded with my iPhone attached to my 25-power Kowa spotting scope, so it may seem a lot closer than it really is. Below is a video of the shot. Needless to say I achieved my goal and was very excited.

Watch Hit on 10″-Diameter Balloon at One Mile with .338 Lapua Magnum

After my balloon shot, I let my friend Justin Fargo, a novice shooter, try his skills. Justin told me that he had never shot past 100 yards using a common deer rifle. Surprisingly, Justin not only kept all his shots under 1 MOA, he hit the 9-inch white circle in the middle of the target. This bullet hole measured only 4.3 inches from the center of where he was aiming. Truly amazing! The target below shows Justin’s shots at one mile. Note that All the hits are located within the 24-inch black circle.

Paul Phillips .338 Lapua Magnum rifle one mile Brux Barrel McMillan A5 stock

What I Learned — With the Right Equipment, Even a Novice Can Make Hits at a Mile
The above results demonstrate that even a novice shooter with a high-quality, custom rifle and match-grade ammo can make extreme long range shots with great accuracy. It is very important to understand the ballistics of the bullet and the effect of wind drift to make precision, first-shot hits on your target. It is also important that you know your target, backstop and beyond when making these shots. To date, I have shot approximately 40 shots at a mile in calm conditions while averaging 3-shot groups between ½ to 1 MOA (1 MOA is about 18.5″ at that distance). My next experiment is to see how well these bullets perform traveling at subsonic speeds out to 1.5 – 2 miles. Stay tuned!

Special thanks to the following people that helped out with this project: Geoff Esterline, David Tooley, Dick Davis, John Droelle, Ray Gross and Bryan Litz.

Editor’s Comment: The point of this article is to show the kind of accuracy a precision rifle system can achieve, consistently, at extreme long range. Though this rifle will do duty as a hunting arm, Phillips is not advocating that a .338 LM be used to harvest animals at the full limit of its supersonic range. Because winds are hard to predict at extreme long range in a hunting situation, Phillips cautions that the practical distance at which he would shoot game with a rig like this is much, much shorter.

Permalink Gunsmithing, Hunting/Varminting 9 Comments »
May 9th, 2012

Ryan Pierce Sets 450-24X F-Open Record with Home-Built Gun

Forum member Ryan Pierce set a pending new F-Class Open National Long-Range record this past Sunday at a Long Range Regional Palma Match in Lodi, Wisconsin. Ryan shot a “clean” 450 with 24 Xs in a 800/900/1000 match at Winnequah Gun Club. Once certified, Ryan’s 450-24X score tops the 449-33X record set by Robert Bock in 2008. To make the story even better, Ryan smithed the gun himself, doing his own metal and stock work! Ryan’s record-setting rig is a .284 Win with BAT action, Brux barrel, and Precision Rifle & Tool (PR&T) stock. Ryan shot Berger 180gr Hybrids pushed by H4831SC and CCI BR2s. Interestingly, Ryan set the record with a ‘dirty barrel’. By the time he finished the 1000-yard stage on Sunday, he had put over 150 rounds through his barrel since its last cleaning. Ryan wasn’t just being lazy — he had noted that the vertical tightened up the more rounds he shot.

Ryan Reveals How Record Was Set
Ryan tells us: “I had actually debated using my 6BR last weekend but didn’t and used up my last box of 180 Hybrids. They are seated .025″ off the lands with 56.0 grains of Hodgdon H4831SC and a BR2 primer. This load is running 2900 fps. I had 1 1/2 min of wind on and was favoring another half minute. I had excellent pit service, 6 seconds, by Jeff Dick. I knew he was fast so I figured ‘let’s rock and roll’. I was done in 3 to 3.5 minutes. I was pretty stoked. Halfway through the relay I started shaking pretty bad. After my last shot came up a 10 I was all smiles and couldnt believe I’d shot the 450.”

Ryan Pierce F-Class Record Open Lodi

Above is Ryan with his rifle and 1000-yard target. He had two (2) sighters in the 9-ring, but the rest were 10s and Xs. Jim tells us: “As the string went on Ryan started flirting with the bottom of the 10 ring. Those pasters were removed to validate that they were indeed solid 10s.” Jim adds: “I witnessed Ryan’s 900- and 1000-yard strings and had the pleasure of signing the score card on the 1000-yard string, it was amazing to watch and see Ryan so excited about accomplishing this.”

Ryan Pierce F-Class Open Record

Ryan Pierce SPEAKS OUT

CLICK “PLAY” to hear Ryan TALK about setting Nat’l Record with .284 Win at Lodi.

[haiku url=”http://accurateshooter.net/Video/pierceaudio215.mp3″ title=”Ryan Pierce Talk About F-Class Record”]

Ryan Pierce F-Class Record Open Lodi

Above you can see Ryan’s 800- and 900-yard strings on the same target. Jim See reports that: “Due to the rain delay, and some relay jockeying, Ryan ended up being the last shooter at 800 and the first shooter at 900, all on a clean target. So when [Ryan] hit the pits he took the picture, not knowing what was in his near future.” NOTE: The 800-yard stage allowed unlimited sighters, so there are a few shots out of 10 Ring. At the 900- and 1000-yard distances, two sighters were allowed at each yardage.

We congratulate Ryan for his great shooting. This was a tough record to beat. Forum member Nodak7mm says: “This was great shooting by an awesome up-and-coming shooter in the F-Class arena. Ryan is definitely a force to be reckoned with….”. Click the link below to hear Ryan talk about setting the record, and some surprising changes he made the day of the match.

Ryan Pierce .284 Win F-Open Rig Specifications
Ryan provided this info on his record-setting rifle: “The gun has a BAT ‘M’ action (Jewell trigger), Brux 32″ 1:9″ twist barrel, and a Ray Bowman (PR&T) F-Open ‘low boy’ stock with adjustable cheekpiece and adjustable buttplate. The scope is a Nightforce NXS 12-42x56mm. The barrel has 1300 rounds through it. All the metal and stock work was done by me.” Ryan’s record-setting load consisted of Berger 180gr Hybrids pushed by H4831SC and CCI BR2s at 2900 fps. This was a straight .284 Winchester.

Permalink Competition, News 13 Comments »