This is a Mosin Nagant M44 stock that had the toe cracked off it, the toe wasn't even with the stock, so a new one would have to be made from scratch.
Here's the stock at my friends house before he shipped it to me
The first thing I did was start on the area of the toe that would need to be filed perfectly flat. As it was very uneven. This is the piece of birchwood that would become the toe.
Here are the tools I used to get the toe of the stock flat. A flat file is really all that's needed. But I had some fingerprinting dust laying around that my aunt had given me, she was a CSI several years ago and used to get a lot of the stuff. What I did was dust the bottom of the slice of birchwood, then placed it on the toe of the stock, and pressing down I rubbed it back and forth across the toe of the stock. The black dust that's on the birch will rub onto the stock, showing where the high spots are.
I then either filed the black area's down until the soot was gone, or used my sandpaper block if I needed more precision and less wood to be taken away than with a file. After this you just re dust the area, rub it on the stock, and repeat the filing or sanding process until the black is rubbing onto the stock very evenly.
When the stock was even enough to satisfy me, I then proceeded to start attaching the birchwood to the stock. The first thing I did was drill some shallow holes in the birchwood, and the stock. This will create a stronger bond, sort of a mechanical lock with the epoxy resin. It's not necessary though.
I mixed up enough Devcon 2 ton clear epoxy weld to completely cover the bottom of the stock, and the bottom of the birchwood piece, as well as fill in the holes. I then clamped it onto the stock with another piece of wood on top to prevent the clamp from gouging the wood. I put some paste wax along the edges of the stock near the seam of the repair, in case any epoxy seeped out, that way if any does seep out it will chip off when dry. Be sure not to get any wax in your crack though.
With the buttplate on just to show how much wood I had to work with. Using a bigger piece of birch would have helped.
Continued....