1. The Forum Rules have undergone some minor changes and updates.  Please take the time to read them; it will only take a couple of minutes of your time. By doing so, you lessen the chance of incurring the wrath of the moderation team or making yourself look foolish to other members.

    90% of users posting adverts in the Sales forums need to be reminded to read the rules as their posts are wrong.  This is unnecessarily time-consuming and will no longer happen - if your advert doesn't follow the Sales Rules it will be deleted and you'll have to start all over again.

    To close this box once you've read it (and the Rules), click on the X in the top right-hand corner.

    Thank you.

    AGF Staff



    Dismiss Notice
  2. A reminder of one of the Forum Rules:

    'Behaviour

    Do not make inappropriate or offensive posts - including threats, harassment, swearing, prejudice, defamation, deliberate insults or name-calling, other negative remarks about this forum, its moderators and administrators or your fellow members. Even if this is just your own personal opinion, RESPECT YOUR FELLOW MEMBERS.'

    There have been changes made to our censoring software in an attempt to help with this growing problem.

    Click the X in the top-right-hand corner to dismiss this notice.
    Dismiss Notice
  3. Dear members,

    Our membership (like our country) consists of people from all walks of life; different in far more ways than can be listed here and each with a different view based on their experience of life - regardless of their colour, religion or cultural heritage. Every single person in the UK has been born of mixed race – we are a multi-coloured and multi-cultural country.

    As many of you are aware there are a handful of individuals amongst this membership that persist in making provocative, inflammatory, racist and otherwise offensive comments. This has been happening across the forum to a certain degree but is most especially prevalent in the Adult section.

    The moderation team has tried to stay on top of this, however unfortunately because of the ‘offensive’ nature of much of its content we don’t monitor the Adult section quite as much as perhaps we should. As a result much of this behaviour has gone unnoticed unless it has been reported to us. While the team always intended to take a "light touch" approach to the Adult section it would seem that some people aren’t quite adult enough to be left unmonitored after all.

    This behaviour is, and always has been against Forum Rules as well as the specific stipulations of the Adults forum and it will no longer be tolerated. We feel it's time to draw a line in the sand and as such from this point onward offenders will receive an immediate and permanent ban from the forum.

    In order for us to achieve our goal of restoring the forum to the friendly and tolerant place it once was, we ask that ALL members be mindful of the content they post and help us to stop unacceptable behaviour by using the 'Report' tool at the bottom of any offending post - the results of which can be seen only by Admin/Moderators.

    You should all receive a copy of this message by PM. 

    To close this message box, click on the 'X' in the top-right-hand corner.

    Dismiss Notice
  4. Hotmail block emails from us entering your inbox. Unless you can setup a safe sender you will not get activation emails from the forum. Please use an alternative provider or complain to Hotmail.
    Hotmail addresses include.

    @Hotmail.co.uk @Hotmail.com @outlook.com @Live.com
    Dismiss Notice
  5. Postings on Politics, Religion & Controversial Off-Topic Material

    The majority of users do not want to read about these subjects and people have left the forum as a result of it – this is after all an 'Airgun' Forum. It’s all very well to say they don’t have to read it if they don't want to, but as most of us use the ‘New Posts’ button there is no easy way to avoid it.

    All AGF staff members are in favour of people being able to discuss what they want, but we have to draw the line somewhere if it is upsetting other users. We don’t want to read about these topics either.

    IMPORTANT- The discussion of politics and religion is no longer allowed anywhere on the forum (including the Adult section).  The only exception is if it's airgun related - they must be put in the Airgun Related Politics section..

    We will not tolerate bullying or personal attacks, racism or any other offensive 'isms'. we will remove these topics from the forum, we will not give you an area where you can abuse each other. We will not hesitate to ban offenders.

    To clear this text box, click on the 'X' in the top right-hand corner.

    Dismiss Notice

Falcon Fn12 - Full Restoration Project

Discussion in 'Gun Gallery' started by Rhys Ent, May 24, 2021.

  1. Rhys Ent

    Rhys Ent Active Member

    Messages:
    49
    Likes Received:
    60
    Location:
    Manchester
    Hi All,

    Thought I would post an update of a recent Falcon renovation project - many of you are always keen to help others in various ways and it may be of interest. My nephew has been begging for his first rifle for ages, so now he has come of age it was time to stick to my word. I acquired what I thought was a walnut-stocked Titan Bearcat in .177 that had been sat unused in a farm house for the last 10 or so years. I had one as a young fella and thought this version looked different. After researching it appears she is actually a Falcon FN12. My decision was to do the little man proud and restore better than new, removing scratches on the action and various original tooling marks, wear and stock blemishes.

    First job was a full seal kit order and complete strip down (every part labelled for later). The main O-rings had perished but surprisingly still held a seal. The original brass fill cap was replaced for a ‘Best-Fittings’ quick-fill version that does away with the inner end-cap springs and valve. The trigger unit was stripped, cleaned and all sear/contact points carefully polished so as not to unduly remove case hardening or alter face angles. All inner springs and valves were cleaned and then various contact faces polished to remove tooling marks. A Rob Lane regulator was fitted (there is a thread on the forum), transfer ports were opened up to 3mm and polished, and the valve stem was also polished smooth. I also wanted the hammer weight to look more finished, so I polished it, taking care as it is also case-hardened. Then it was off to the chrome platers - for £5 it adds a nice touch given part of it is on show. The pellet bolt, inner bolt guide and cocking lever also had their respective tooling marks removed.

    All metalwork was then sent to Paul Chell for his quality polishing and blacking skills – great job Paul and return packaging, thanks. A big thanks to ‘Ped’ on this forum too for answering my seal and leak questions - much appreciated Sir. And another big thanks to Dave Gee, especially as I shot his chrono, but cashed up for new ;)

    Reassembly went okay, but must add on first impression the quick-fill kit is a great improvement, plus it looks much tidier. Overall I am pleased with the finishing touches and it’s nice to restore an old classic and pass her on to the next generation. Just wouldn’t want to be a rat on his patch now as he has a real keen eye!

    Stock renovation:
    First job was to carefully sand the full stock and get her back to original wood. It is not the greatest piece of walnut by any means, but I wanted to get the best out of it. It is distinctly two-tone, the left side is dark and the right much lighter. The original chequering was shocking and I imagine machine hand cut by an old milkmaid. The edging lines were all out of whack and rough in the corners. The chequering itself had loads of unfinished lines leaving blocks of joined areas. Given the angles were rather wide, I decided to make a chequering tool from a 10mm x 4mm piece of tool steel. I could then set the angle so it would remove the groove faces and re-set the finish. I also re-established the edging lines as best I could so that the depth/look were similar. The areas with joined/uncut diamonds were then re-established. Next job was the shoulder pad. This was stained and grubby, so it was soaked in hot soapy water before wet sanding with fine paper.

    After sanding with various grades to try and remove the classic pores/xylem tubes you get in walnut, I was still unhappy with the plain look of the stock. Now the nephew has a penchant for fine English shotguns, so I decided to add a little shape to the forend to personalise it (more noticeable in the flesh). The other task was to add a cap to the base of the pistol grip. I wanted to make it look similar to the layers on the shoulder plate, so I decided on mirroring it with ebony, holly and Brazilian Mahogany. I removed 10-15mm or so from the original base, then recessed the inner to allow me to socket the Mahogany into place. I have done this before, and after fixing you would need to smash the stock to bits to remove.

    The ebony and holly disks were hand-cut and needed to be meticulously hand-sanded to ensure they were flat and consistent in thickness (Vernier’s come in here). The dust from each of these was like flour, so I collect this for later.

    I made a quick stock holder to act as a second set of hands. In the image with the white paint on the pistol grip – this was done to enable me to ensure the surface was completely flat and equalise high and low spots. I used a flat steel plate and 180grit paper. With consistent slow pressure, you can then sand totally flat and see any white areas you need to remove. The surface was then marked with tiny drill holes to allow the epoxy to penetrate. The next stage was to get a flat plate with a hole in the middle for a screw. Under this would be a firm piece of close-cell foam. This enables even pressure to be applied once the first glued pieces are tightened down. Without the foam it easy for any uneven pressure to cause the layers to lift slightly. If this were to happen the layers would be uneven and balls up the look.

    The black ebony and white holly were also marked for epoxy contact, taking care not to score the outside of your finish area as this would be seen on the line edges during final finishing. Both disks were slightly oversize to allow for any movement during gluing and paring back. The epoxy wood flour was then mixed into the glue to achieve a darker colour – the mating faces were very tight so I could have done away with this, but it never detracts and in my opinion is worth adding. I then carefully screwed down the plate (pre-drilled in the stock, but will be hidden with the end cap) and foam, making sure the two disks were in position before the 5 minute epoxy started to set. After 24hrs, the disks were trimmed back a touch closer to the stock and the inner section removed to expose the socket joint. The Mahogany was shaped with the grain running linear to the base, plus haphazard holes were applied to both the cap and the socket to allow the glue additional contact. After careful fitting (zero room for error as no compression in these hardwoods) and testing, I pre-set the stage for holding the cap in place. This was tricky due to shaped angles, so I shaped a block of firm close-cell foam and tested with a Quick-Clamp. After feeling comfortable it would hold and not slip/slide, I mixed up more epoxy now with Mahogany wood flour and fixed into position. Again, it was left for 24hrs before removing and carefully shaping the outer faces. The various woods have their own density so you need to be careful when sanding not to hollow areas as you want everything to flow smooth to the touch with no exposed areas – a small piece of hard flat foam behind your sandpaper can help.

    Next job was to lightly wet the stock to raise the grain a final time, before dry sanding with 600grit. The stock was then smothered in boiled linseed oil with 15% artist’s turpentine, whilst oil sanding wet with 600grit. This was done twice, before a final wet oil sand with 1000grit. The oiling process is still not complete but my brother will need to continue it in France as the butt end grain is still drawing in oil after 8 coats that have been allowed to dry in between. The white holly has turned more creamy coloured after the oiling, but it’s impossible to stop unless you resin-fixed the wood or used plastic.

    Overall, I have tried to make the best of a low-grade piece of walnut and she has definitely benefitted from some TLC. The chequering was really rough so now looks more finished, plus the young nephew now has something different with a few finishing touches.

    All the best guys
    Rhys
     

    Attached Files:

    BrettMRC, Mortimer, Cinimod and 13 others like this.
  2. Rhys Ent

    Rhys Ent Active Member

    Messages:
    49
    Likes Received:
    60
    Location:
    Manchester
    A few more images to the stock process.
    Cheers
     

    Attached Files:

    Uriel, ped, The Robin and 2 others like this.
  3. William65

    William65 Out with the dog...

    Messages:
    1,986
    Likes Received:
    2,141
    Location:
    South Wales
    Cracking work :thumb:
     
    Rhys Ent and Blue BSA like this.
  4. Rhys Ent

    Rhys Ent Active Member

    Messages:
    49
    Likes Received:
    60
    Location:
    Manchester
    Meant to add, I posted the regulator process last week, but here is a power chart with 8.44grn JSB Exacts after regulator set-up and adjustments. Basically, good for 32-33 shots given the tiny air cylinder, then quickly tails off
     

    Attached Files:

  5. Devondumpling

    Devondumpling Loves his bullpups !

    Messages:
    509
    Likes Received:
    477
    Location:
    Plymouth S. Devon
    Very nicely done and better than new :thumb: .
    Cracking rifles I’ve had a few of these in different guises :thumb:

    Mike
     
    Rhys Ent likes this.
  6. MrBadger

    MrBadger Busy Member

    Messages:
    696
    Likes Received:
    788
    Location:
    Tiverton, Devon
    Love these rifles, and you’ve absolutely done it proud! Amazing work, sir
     
    Devondumpling and Rhys Ent like this.
  7. The Robin

    The Robin Super Moderator Staff Member Mod/Admin

    Messages:
    34,363
    Likes Received:
    14,121
    Location:
    Yorkshire
    Very interesting read and top job :thumb:
     
  8. Rhys Ent

    Rhys Ent Active Member

    Messages:
    49
    Likes Received:
    60
    Location:
    Manchester
    Thanks Mr Robin - thought I would type up my thoughts for those interested. Cannot wait to see the video of the nephew opening his present/s (he lives in France), I was over the moon with an open sight BSA Meteor!
    The thing I could not change was the chequering position on the pistol grip as whoever had set it out at the factory had done so on irregular on both sides. However, the little fella will not notice.
    All the best
     
    ped and The Robin like this.
  9. Wilco

    Wilco Happy airgunner

    Messages:
    5,179
    Likes Received:
    7,590
    Location:
    Exeter, devon
    What a fantastic job and write up mate, it looks brand new and your nephew is 1 very luck lad.

    Realy well done buddy:claping:
     
    Rhys Ent likes this.
  10. steptoe2019

    steptoe2019 Posting Addict

    Messages:
    1,543
    Likes Received:
    1,661
    Location:
    west midlands
    It is so nice to see someone show such love to a rifle and the wife thinks it is only me that does lol .

    I am sure the lad will be over the moon
     
    Rhys Ent likes this.
  11. ped

    ped Big Poster

    Messages:
    3,697
    Likes Received:
    2,847
    Location:
    leeds
    nice one Rhys you've made a grand job of that and the young uns going to be well happy with it
     
    Rhys Ent likes this.
  12. Rhys Ent

    Rhys Ent Active Member

    Messages:
    49
    Likes Received:
    60
    Location:
    Manchester
    Cheers guys, appreciate the positive feedback. It was you Steptoe that sent me in this direction and highlighted Ped who helped me locate a leak.
    The boy has been waiting since the end of 2019 for his 1st rifle and The Flu scuppered it as he is in France. I actually went to similar lengths to restore a HW77 for him, but realised it would be far too heavy in the end so sold it and moved onto project Falcon. I imagine it will be the present to end all presents after that wait. He also has all the trimmings to go with it :D
     
  13. louisvanhovell

    louisvanhovell Posting Addict

    Messages:
    1,049
    Likes Received:
    1,716
    Location:
    Amsterdam, The Netherlands
    Thank you Rhys, what a great post, and resto project.
    Nice to read that some well respected members on here have contributed.
    The end result looks beautiful. Congrats and enjoy
     
  14. Rhys Ent

    Rhys Ent Active Member

    Messages:
    49
    Likes Received:
    60
    Location:
    Manchester
    That comment makes typing it up worthwhile Louis - top man :thumb:
     
    louisvanhovell likes this.

Share This Page

  1. This site uses cookies to help personalise content, tailor your experience and to keep you logged in if you register.
    By continuing to use this site, you are consenting to our use of cookies.
    Dismiss Notice