Can you saw a shotgun barrel? Yes, you can saw a shotgun barrel, but you must follow strict federal laws regarding minimum barrel length and overall length. Breaking these laws can lead to serious trouble. This guide will show you how to approach shortening shotgun barrel work safely and legally. We focus on proper tools and the legal limits you must respect.
Grappling with Firearm Modification Laws
Altering a firearm is serious business. In the United States, the Bureau of Alcohol, Tobacco, Firearms and Explosives (ATF) sets the rules. These rules stop people from making illegal short-barreled shotguns (SBS). An SBS is a shotgun with a barrel less than 18 inches long, or an overall length under 26 inches. These limits are key to legal shotgun barrel length.
If you modify a shotgun to be shorter than these limits, the ATF considers it an SBS. Making an SBS without paying a $200 tax stamp and registering it with the ATF is a major federal crime. Always check your local and state laws too. They might have stricter rules.
| Shotgun Part | Minimum Legal Length (Federal) | Danger of Violation |
|---|---|---|
| Barrel Length | 18 inches | Felon charge (SBS) |
| Overall Length | 26 inches | Felon charge (SBS) |
Choosing the Right Project: Why Shorten a Barrel?
People often want to shorten a shotgun barrel for specific uses. Common reasons include:
- Home Defense: A shorter barrel makes the shotgun easier to handle inside a house. It swings faster in tight spaces.
- Making a Coach Gun: Some want a classic look, like the short-barreled double-barrel shotguns known as making a coach gun.
- Cosmetic Change: Simply changing the look of the firearm.
If your goal is to make a coach gun, you must ensure the final barrel is still 18 inches or longer.
Gear Up: Tools for Safe Shotgun Modification
Safety comes first when cutting metal. You need the right tools for shotgun modification safety. Using the wrong tool can ruin your barrel or cause it to fail later.
Essential Tools List
- Measuring Tools: High-quality tape measure or calipers for measuring shotgun barrel. Accuracy is vital here.
- Cutting Tool: A good quality hacksaw for shotgun work is common, but a reciprocating saw with a metal blade works faster. For precision, some use a lathe or specialized cutting jig.
- Securing Device: A sturdy bench vise to hold the barrel still. Protect the barrel finish by using wood blocks or soft jaws in the vise.
- Finishing Tools: Files (flat and round) for smoothing edges. A reamer is needed for the crown.
- Safety Gear: Safety glasses are a must. Gloves protect your hands.
Step-by-Step Guide to Shortening Shotgun Barrel
This process requires patience. Rushing leads to errors and dangerous results. Remember, we are aiming for 18 inches or more.
Step 1: Precise Measurement and Marking
You cannot guess the length. Measure from the face of the breech (where the bolt closes) to the muzzle.
- Place the shotgun barrel securely in the vise. Use soft jaws to prevent scratching the metal finish.
- Measure the current length. Decide how much material you need to remove. Always cut less than you think you need. You can always cut more; you cannot easily add metal back.
- Mark a clear cutting line on the barrel. Make sure this line is perfectly square (90 degrees) to the barrel’s axis. Use a machinist’s square or wrap a piece of tape tightly around the barrel to guide your cut.
Step 2: The Cutting Process
If using a hacksaw for shotgun work, use slow, steady strokes. Let the saw do the work. Do not press too hard.
- Start the cut slowly on your marked line. Keep the saw blade straight.
- If you are cutting a long way down, stop often. Check that your cut is staying straight. If the cut starts to drift, correct it gently.
- Cut just past your final target length. Remember, you will finish the end precisely later.
If you have access to a lathe, this is the ideal method. A lathe ensures a perfectly straight and smooth cut.
Step 3: Establishing the Proper Length
After the rough cut, you must confirm the length precisely.
- Clean the end of the barrel.
- Secure the barrel back in the vise, ensuring the muzzle end is where you need to work.
- Use calipers to measure from the breech face to the freshly cut end.
- File the end down slowly until you hit exactly 18 inches (or your chosen legal length). Check the measurement multiple times.
The Crucial Finishing Work: Crowning and Sights
A rough cut muzzle can cause dangerous malfunctions and terrible patterns. You must finish the muzzle properly. This finishing process is called crowning a shotgun barrel.
Why Crowning Matters
The crown is the final edge of the muzzle. It guides the shot column evenly as it leaves the barrel. A damaged or uneven crown causes gas to escape unevenly. This ruins shot patterns.
How to Crown a Barrel
- Chamfering: Use a large round file or a specialized interior chamfering tool. Gently round the inside edge of the muzzle. This removes sharp burs left by the cut.
- Recrowning: This is advanced work. Ideally, use a lathe tool specifically designed for crowning. If you do not have access to a lathe, you can use a specific crowning tool kit designed for muzzle finishing. These kits generally involve pressing a precision cutter into the muzzle end.
- Filing Sights (If Applicable): If you removed the front sight bead or post while cutting, you must replace or reattach it. If you removed a large rib that held the sights, you will need to filing shotgun sights down if you opt for a low-profile bead, or weld a new base for a different sight. Ensure the new sight is straight.
A Note on Smooth Bore vs Rifled Shotgun Barrel: Most defensive shotguns have a smooth bore vs rifled shotgun barrel. If you are cutting a smooth bore, the crowning process is slightly less complex than for a rifled barrel (used for slugs). Still, a clean crown is necessary for optimal pattern consistency, no matter the bore type.
Addressing Stock Modification (When Shortening the Barrel)
If you are shortening shotgun barrel down to the 18-inch minimum, the overall length might still be too long, especially on a full-length rifle stock. To meet the 26-inch minimum overall length, you might need to shorten the stock. This is how people end up making a coach gun, which often has a very short buttstock.
Modifying the Stock Safely
- Measure Overall Length (OAL): Measure from the back of the buttplate to the muzzle. If it is over 26 inches, you need to cut the stock.
- Mark the Cut: Mark where you want the stock to end. Be very careful. If you cut too much, the gun becomes hard to shoulder properly. A comfortable grip is vital for control.
- Cutting the Stock: Use a fine-tooth saw (like a jigsaw or band saw if wood) to remove the excess. Cut slowly to avoid splintering the material.
- Shaping and Finishing: Once cut, use rasps and sandpaper to reshape the end of the stock. Round the edges to make it comfortable to hold. Apply finish (stain, oil, or paint) to protect the raw wood from moisture.
Legal Considerations: Documentation and Paperwork
If your modification results in a barrel of exactly 18 inches, you are fine under federal law, assuming you did not alter any other part to fall below the 26-inch OAL. However, documentation is your best defense if questioned.
Keeping Records
Always keep records of your work. If you are doing shortening shotgun barrel work yourself:
- Take “before” and “after” photos.
- Note the date of the modification.
- Keep receipts for any tools or materials used.
If you ever sell the shotgun, you must disclose that the barrel has been modified, even if it meets all legal requirements.
Common Pitfalls in Shotgun Modification
Many DIY jobs go wrong because people ignore small details. Avoid these common mistakes:
- Cutting too short: This is the fastest way to commit a felony. Always err on the side of leaving it slightly longer than 18 inches during the cutting phase.
- Ignoring the Crown: A poorly finished muzzle is dangerous. It can cause unpredictable shot patterns, which is especially bad in self-defense situations.
- Improper Vise Use: Clamping the barrel too tightly or without protection can warp the metal, affecting the bore.
- Not Checking OAL: People focus only on the barrel, forget the stock, and end up with an illegal firearm because the overall length dropped below 26 inches.
Fathoming Bore Type Differences: Smooth vs. Rifled
When modifying, it is crucial to know if you have a smooth bore vs rifled shotgun barrel.
- Smooth Bore: These are standard for buckshot and birdshot. The interior is smooth. When cutting, you only worry about the muzzle crown.
- Rifled Barrel: These are designed for slugs. The rifling spins the slug for better accuracy. If you cut a rifled barrel, you must ensure that the rifling remains intact for at least an inch or two past the new muzzle crown to maintain the spin effect. Cutting too much can effectively turn a rifled barrel into a poor-performing smooth bore.
If you are unsure, inspect the inside with a bright light and a magnifying glass. If you see spiral grooves, it is rifled.
Summary of Safety Protocols
Shotgun modification safety is non-negotiable. Follow these rules every single time:
- Unload Completely: Verify the chamber is empty and the magazine tube is empty. Lock the action open if possible.
- Check Local Laws: State laws often supersede federal minimums.
- Use the Right Tools: Do not use tools meant for wood or plastic on metal barrels unless they have the correct blades/bits.
- Measure Twice, Cut Once: Seriously. Measure your intended legal shotgun barrel length repeatedly.
- Finish the Muzzle: Always recrown the barrel after cutting.
If you are at all uncertain about the legality or your ability to properly finish the muzzle, it is safer and often cheaper in the long run to purchase a factory-made short-barreled shotgun (with the proper tax stamp) or a legally compliant barrel designed for your shotgun model.
Frequently Asked Questions (FAQ)
Q: What is the absolute shortest I can make my shotgun barrel legally?
A: The absolute shortest legal shotgun barrel length permitted by federal law is 18 inches. The overall length must also be 26 inches or more.
Q: Can I use a pipe cutter to cut the barrel?
A: It is not recommended. A pipe cutter often deforms the barrel’s round shape, which ruins the internal bore. This will cause severe patterning problems and might compromise the barrel’s strength. Use a hacksaw or lathe.
Q: What happens if my barrel measures 17.9 inches?
A: If the barrel measures under 18 inches, the ATF considers the firearm an unregistered Short-Barreled Shotgun (SBS). This is a serious federal offense carrying heavy penalties, even if the error was accidental.
Q: Do I need to do anything special when cutting shotgun stock?
A: When cutting shotgun stock, the main goal is to maintain comfortable handling while ensuring the overall length stays above 26 inches. Always reshape the raw edge to prevent splintering and finish it properly to protect the material.
Q: Is filing down the front sight safe?
A: If you are filing shotgun sights down because they interfere with your vision or modification, it is generally safe to do so, provided you do not cut into any load-bearing part of the barrel or rib structure itself. However, you must have a proper front sight for aiming if you intend to shoot the gun safely.