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the barrel opening 'has' to be square or the gas wont escape evenly at the pellet base when it leaves .. you arnt going to achieve that with grandpas hacksaw trust me and if its cut properly with a lathe or jig then your going to put chamfer on it to finish the edge period ..
Grandpa did. Muzzle loaders shot fine. Most gunsmiths in those days built their own shop, made their own tools, and made and rifled their own barrels, all with hand tools.
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