I made an alignment tool on the lathe and milled out a new top strap with threads in it.

The top strap was ground till it fit just right on top of the alignment tool threads and the frame. It was then TIG welded using high strength rod.

After welding the general shape of the frame was restored with grinding and polishing. A tap was used to clean up the threads inside the frame. I then turned out a new barrel from match-grade stock. I decide to change the caliber from .45 LC to .357 mag.

Here is the barrel fitting in the frame. I bought a new .357 cylinder and checked the barrell to throat alignment and it was pretty darn good! I cut an 11 degree forcing cone using brownells chamfering tools.

Here is the frame and barrel set up in the mill for milling the grove and sight notch in the top strap and for milling a slot in the barrel for the front sight.

Here is the gun reassembled ready for test firing with the new .357 cylinder. The cylinder has less than .001 end shake and the cylinder to barrel gap is about .002.  It is a pretty tight gun.

The test firing went great! Turned out better than I had hoped, shooing very tight groups. It will need a little more polishing before I tear it down to blue it. .