New Rear Sight for my Hawken Rifle

Several years ago I bought a Cabela's Traditional Hawken rifle in .50 caliber. It isn't a faithful copy of the real Hawken rifles of the 19th Century, but nevertheless, it's a well made and nice shooting gun. It's more or less a variant of the Lyman Trade Rifle, but fitted with a cap box on the stock and double set trigger. Also, unlike the Lyman, it was available with a left handed stock and lock. Both the Lyman and Cabela's rifles were made by Investarms in Italy.

One thing I did not like about the rifle was the sights. The rear sight, in particular, was a poor design. The adjustable rear notch was a wide open "V". IIRC, the Lymans's have rear sights that are dovetailed in, which makes replacement with a fixed but better sight easy. Unfortunately, the Cabela's rear sight was held on with two screws and nobody made a good replacement.

So, I decided to install a Lyman Model 66SML aperture sight, made for the Lyman Great Plains Rifle, Trade Rifle, sidelock Thompson-Centers, and similar rifles.

The Model 66SML is mounted on the tang with two screws. It uses the rear wood screw which goes through the tang into the stock, plus an 8-32 screw into the metal of the tang. The tang on my rifle wasn't drilled and tapped so I did that today.

Using a #29 drill on the tang:

Before drilling the hole, I located it by mounting the sight on the tang and marking the spot with a transfer punch. I then dismounted the tang from the rifle and used a pilot drill to ensure the #29 drill wouldn't skip. Only then did I put the twist bit in the chuck.

I then tapped the hole with 8-32 threads. I used #3 Morse taper lathe center held in the mill's head to guide the tap so it started off straight:

I used a little Tap Magic on the tap, but I could probably have done it dry with no problems. OTH, there's no reason not to use a lube and save a little wear on the tap.

A closeup of the newly mounted sight:

And finally, the whole rifle:

This rifle has a 1:48 twist, so it can shoot either patched round balls or conicals like a Hornady Great Plains Bullet or T/C Maxi balls. So far, I've just shot it with PRB and it did well.

Simple work like this is a main reason I bought a small lathe and mill back in 2013. It took me about 45 minutes to do this, which included digging out the rifle and rear sight, schlepping them out to my shop, and doing the work. In contrast, to have a gunsmith mount the sight it would require locating a 'smith locally or shipping the rifle, getting onto his wait list, and probably paying about $75 to $100. Since shooting is my hobby, I will eventually do enough jobs like this to largely offset the cost of the tools.

Of course, that doesn't even account for the satisfaction of doing it myself.