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My thoughts so far on process for cutting pin slots in barrel:
1) I need to build a tool to be able to mark where the pin slots will go on the barrel. I think the best way to do this is to cut on a used front sight so that the blowhole is visible and can be lined up, then cut some bottom off so that I can mark the exact place to cut the pin slots.
2) Since I have a lathe, I'll chuck the barrel in it as a vice, then use a Dremil tool to cut the pin slots a couple of thousands shy of the depth needed.
My tool created in #1 can then be slipped on the barrel, and pins inserted until it "feels right".
Sounds like a 'this week-end' project.
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