Rossi Rifleman

I couldn't bring myself to spend $30 on the button plug for the safety so went to Lowes and bought a package of two 5/16-28 (fine thread) stainless steel bolts, cut the head off one of them, stuck the smooth end of the bolt in my drill chuck, then turned the threads down against a grinder wheel until it fit the hole snugly. Cut it off flush, used red Locktite to hold it in place, ground and sanded with wet or dry paper to 600 grit. It still looks rough up close, but so do the factory tool marks in the rest of the gun, which you can see in the photo. Also you can still see part of the "F" marking. I may redo this and use the smooth end of the bolt in the hole for a cleaner fit, although I still think this looks better than the button plug or the .25 casing.

Great work.

And yet another idea from the Rossi maintenance crew !

I still like the .25ACP but haven't done anything yet.

Did have another thought ... back out the aperture
and replace it with a machine screw. Not sure the
thread size of Steve's aperture ... anyone ?

I really like your idea kenny! I wonder if you could go ahead drill the hole large to eliminate the detents and match the shank on a larger bolt.

I'm going to retitle this topic to "My 92 safety plug" and move it to our "DIY Gunsmithing" forum as things kind of get buried in this 92 forum as it is the most active.

AK you're just being nice. RD, that's a good idea to drill the hole slightly larger to get rid of the detents, and grind down a larger bolt Someone else mentioned peening the inserted bolt/plug to close the gap, but I don't think my Locktite would hold well enough for that. If I drill it out larger, I would have a stop to keep the bolt from slipping down and interfering with the firing pin. Looks like I'm going to be redoing this. I love DIY projects. Thank you Rossi for enabling me to do lots of work to do on my 92.

kenny wrote:Thank you Rossi for enabling me to do lots of work to do on my 92.

Now that is funny…

Good idea Kenny and RD. Maybe we should just start building our 92's from scratch.

I do the same but just use the existing safety, cut down. It blends pretty well, and takes little work.

Hmmm. Jes thinking. If one turned down the head of the bolt until it was just a flange, just larger than the detents and mebbe 1/16" thick, it would look nicer and prevent the plug from dropping down into the action...

I bought all three of mine from Steve !
The work good and look good .