1911 plunger tube broke off, need advice

Detritus

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Well, 9 years and more rounds than most owners will fire in a lifetime before the first significant parts failure, is a decent record for a $500 1911...

Background: took my Metro AC2 out of the case for some dryfire about an hour ago, and when I did the chamber check the slide and safety acted odd for second and then the plunger tube dropped off....:oops: the two legs/frame pins broke off of the tube pretty much at the joint with the tube. based on the appearance of face(s) of the two stubs left behind in the frame I'm just about certain that
  1. the plunger tubes that Metro uses are MIM
  2. at least one pin (the front one), had a void at the join with the tube
So since I'm going to have to replace the dang thing, and have never had to do so before, what can those that have tell me about this particular repair task. what all is actually involved. any advice on technique, replacement sources/options, tricks to make it go smoother, etc. is welcome. TIA
 
You’ll need a staking tool if you’re going to do it yourself. Let me know of you want to borrow one.
https://www.brownells.com/gunsmith-...-tube-staking-tool-accessories-prod79068.aspx
thanks for the info, and the offer :)

Are you able to get the remaining parts out of the frame?
Since there are two ways to interpret that question i will answer both..
If you mean "can I detail strip the gun without further instructions" Yes.

If you mean "can I get the remainder of the plunger tube out the frame".. I think so.
nothing else is falling out on it's own. But I am not "at home" at the moment and cannot just walk out to the shop and give the punch set a try. so not yet sure if I'll be able to drive the two pin stubs out of their frame-holes (don't even know if Metro staked them or epoxied them like some other makers do their plunger tubes and ejectors) or if I'll have to drill them out. I do have eventual access to the tooling that should be needed for either course.
 
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I think I bought a random tube off eBay for my build.

Not being one to buy tools unnecessarily I put a bit in the tube, ground a channel in a thin piece of wood, and used a steel BB and vice grips to stake the legs. I also made sure there was a nice chamfer to the holes inside the frame so displaced metal had somewhere to go. Had I plans of frequently performing the task or a desire for more tools I'd buy the right one.
 
I was surprised to learn from @John Travis that the left side grip is supposed to provide support for the plunger tube, so that it doesn't break off. Mebbe he can explain it more...
 
I was surprised to learn from @John Travis that the left side grip is supposed to provide support for the plunger tube, so that it doesn't break off. Mebbe he can explain it more...
I’m sure that he’ll respond, but from my meager experience I’ll tell you that it doesn’t prevent it from coming loose, but it probably keeps it from getting snagged or whacked by stuff.
 
I was surprised to learn from @John Travis that the left side grip is supposed to provide support for the plunger tube, so that it doesn't break off. Mebbe he can explain it more...
I’m sure that he’ll respond, but from my meager experience I’ll tell you that it doesn’t prevent it from coming loose, but it probably keeps it from getting snagged or whacked by stuff.

my understanding is that the groove and lip at the top of the left panel provides support and an amount of protection to the plunger tube. helps keep stuff from whacking it in use/carry, and keeps it in place longer if it starts to loosen, which can give the user or an armorer a chance to catch the failure before it deadlines the gun.

Being aware of that design feature was why I bought a set of VZ grips for this gun, and Esmeralda made grips for the wife's nearly identical one (she shot mine and fell in love). the Metro factory panels as well as being crappy wood in a "special kind of ugly" pattern, do not come up high enough to do more than just kind of touch the bottom of the tube. This is at least partially due to the factory versions of the safety and slide catch having extended shelves, and almost meeting over the middle of the plunger tube, requiring the reduction or removal of the "lip" at the top of the left grip panel.

As noted, in this particular case the tube stayed in place for 9 years with an average monthly round count of 200rds. and it looks like the plunger tube started it's life with a defect (void in front leg), there's no telling how long it stayed in place likely being held only by the grip panel and the rear leg.
 
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from my meager experience I’ll tell you that it doesn’t prevent it from coming loose,

If the grip panel and the bushing hole locations are to spec it will.

John Browning wasn't an idiot.

The grip will be a light press fit onto the frame, and provide positive support from below, and when thescrews are cinched down, will pull the lip against the side of the tube so that in the unlikely event that it does loosen, it won't walk out of the frame.

Some years ago an old gentleman brought a 1918 Black Army Colt to me for a teardown and inspection/cleaning. The gun had belonged to his father who was a veteran of The Great War, and he'd managed to get the pistol back home with him when he was discharged. When I took the left grip off, the plunger tube fell off on the table. According to him, it had been that way for years, but because the grip had held it in place, he didn't worry about it much. It wasn't repairable because the legs had rusted flush with the inside of the frame. I had a few NOS USGI surplus tubes on hand, so I replaced it. I doubt that it was period correct, but at least it was a GI-spec tube and it would have taken an expert to spot it. At the time, those old pistols didn't have the collector value that they have today anyway.

For this, the WW2 era synthetic stocks were better than the original wood stocks because they didn't shrink with age.

The tubes have to be properly staked, something that seems to have been lost in translation these days. You have to create a "well" in the holes for the legs to rivet into and pull the tube against the frame. You can do this one of two ways. Use a ball grinder on a Dremel to chamfer the holes lightly, or swage the chamfer with the tapered steel pins on the staking tool before staking the tube legs. I prefer the latter. It's easy to go too deep with the grinder and weaken the mount to the point of actually pulling through the frame or cracking it adjacent to the holes.

The other problem is that few grips are made to correct specs these days, but hard ones...plastic or wood...with a lip can be made to work by cutting a thin strip from shim stock and using it to provide support. If you're careful, it's not easily noticeable. In a pinch, you can even use cardboard, but it will need to be replaced periodically. Support from the bottom is most important. Support from the side is a typical Browning redundancy for a "just in case" situation.
 
Well had a chance to take the gun out to the workshop this after noon, the leg stumps are now out of the frame. what I found was shall we say instructive. Upon closer examination of the two "stumps" it would appear that the plunger tube is in fact MIM, and that both legs suffered from voids to varying degree and location. the front leg looks to have only been connected with the body of the tube in one small spot, the rear leg was connected in a continuous strip front to back comprising about a third of the width of that "face" as well as having a serious conical void on it's opposite face that was deep enough to make that leg looks recessed in the frame (in appearance not unlike the pits from shrinkage found on the ends of an injection mold sprue) .

gun is now detail stripped in a "project bin" in my workshop. I'm thinking that I'll do a few other minor upgrades while i's at it, including (I hope) removing and replacing the last of the crappy factory grip bushings (one out of four bushings was actually properly staked, but has gotten buggered up and i'm hoping I don't have to drill the blasted thing out)
 
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