This project started out several months ago as an effort to copy some of Sharps40 (a local Amateur Gunsmith) work by installing a colt 1860 army grip frame on a blackhawk. So I ordered the parts and as usual, i ordered the wrong back strap. It was an 1860 Navy. When I went back and ordered the right backstrap, I was told it was on backorder. Not wanting to waste a learning experience, I figured what the hell lets try making a bisley backstrap.
The first attempt was to try to modify the Brass navy back strap. I silver brazed on a new lower front lug to the backstrap, milled out the slot, and cut off the upper ears. I quickly discovered that cast brass is very fragile when heated to bending temp. Dont drop hot cast brass. After about the 3rd brake i stopped trying.
After that "learning experience", I moved on to trying it in steel. I found that NC Ordinance (repro grips) has some grip templates that you could print out. I printed out the Colt early Bisley, Colt Bisley, and Ruger Bisley grip shapes to use as templates for the bends.
Not having a steel supplier nearby i had to resort to the big box store rack O steel. I picked up some 3/16 X 1 (5mm X 25mm) hot rolled. I got it home and started heating and bending. I did not want to reduce the with until after the bends since one end would be 1 inch wide (25mm). I have found that for me, i would never be able to get all the bends the way I wanted if the piece isnt full size.
After I got the bends to line up with the template, I milled down the width to close to where it needs to be. Then I needed to mil in the flats on the upper section. I am not showing my milling setups because they are sketchy as Frig.