On with the project! When we left off I had the gun essentially finished but for the abbreviated loading lever and front sight. Good thing that I had one to practice on, because I messed up the one from my gun. So I took the loading lever from my friend’s gun and went to work on it. First I bored a 3/16″ hole down the length of it, mounted it and marked the tip of the cylinder axis pin and drilled a 3/32″ hole in the end of that. I took a piece of 3/16 inch steel rod, chucked it up in the drill-press and turned the end down to 3/32″, then polished it to insure it would slide freely and engage the 3/32′ hole in the cylinder axis pin to lock things firmly in place.
I made a cross-pin out of a pair of nails and secured it, slotted the loading lever to accommodate the cross-pin. The retaining assemble was then trimmed to length, inserted with a coil spring and pinned in place with a 1/16″ brass escutcheon nail. The head of the nail acts against the barrel as a stop when the loading lever is closed, and is held by spring-pressure when it is open. It can easily be pried out with a fingernail or knife-edge for disassembly.
So, the next part of the project is to mount the front sight on this gun and convert my friend’s gun.
Addendum: Done except for front-sights and a little finishing work.
Here are some detailed shots of the retaining mechanism for the loading lever.