Proper Procedure to Change a Dan Wesson Barrel:
(CAUTION: BE SURE REVOLVER IS NOT LOADED BEFORE ATTEMPTING TO CHANGE BARREL.)
1. Assemble the barrel wrench to the barrel nut in the muzzle of the barrel.
2. Unscrew and remove the barrel nut.
3. Remove shroud by sliding forward off the barrel.
4. Unscrew the barrel from the frame.
5. Screw new barrel with end containing most thread into the frame
6. Insert .006 (.002" for SuperMag)' feeler gauge against the front of the cylinder and screw barrel into frame until there is a slight pressure against the feeler gauge, if you want to follow DW specs, but less than .006" may be more conducive to accuracy.
7. Keeping the gauge in place. install new shroud over barrel and locating pin
8. Assemble barrel nut (slots up) using wrench, Tighten so that firm pressure is required to unscrew the nut. DO NOT OVER-TIGHTEN.
9. Recheck gap between cylinder and barrel by moving gauge There should be slight pressure against the gauge, but it should be possible to move it.
10. Remove feeler gauge.
11. After firing the first six or twelve rounds, recheck for proper gap and barrel nut tightness. Make certain the gun is unloaded for this recheck.
12. If the barrel nut is too tight, making removal difficult, use the following procedure: Be sure revolver is not loaded before attempting to free barrel nut.
a. Soak overnight the barrel nut end in WD-40 or some similar compound, then try gingerly using the wrench. Make particularly sure that the nipples stay seated in the nut slots and that you place downward pressure on the wrench while turning.
b. With wrench assembled to the barrel nut, using a mallet, tap back of wrench sharply to loosen nut.
c. Submerge nut end into boiling water or heat with a heat gun or hair dryer to cause nut to expand for easier removal.
d. Search on google for a threaded rod/nut DIY device that will remove the barrel in one piece from the frame without removing end nut. The rod goes all the way through the barrel with nuts tightened on both ends.
WARNING: THE BARREL AND CYLINDER GAP IS CRITICAL. FAILURE TO USE THE GAUGE CAN CAUSE EXCESSIVE GAS LEAKAGE AND LEAD SPITTING, POSSIBLY CAUSING INJURY!
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