Dave,
you are correct in that the problem of cutting threads off center-line is a beginner problem, but I have seen a drawer-full of brand new sleeves at the shop where I had worked that had just been bought from Olin during the last sell-off of stock parts for Model 12's.
Bunches of them with various numbers had ALL been cut on that bent adapter. I'll bet that somebody had run the carriage into the spindle area and "lightly" crashed against the parts jig.
No one bothered to run an indicator on the exterior prior to machining the parts, and the run-out of just a few thousandths is not easily seen, unless you care to look closely. Factory workers and all that, plus lackluster lighting, so I won't assign blame until it reaches the parts inspector.
If the factory had done comparison against a master, the sleeves would all match when they had the same number designation (and mine don't), and they could have made them pull in the barrel maybe .005" each progressive jump, so minimal fitting would have been needed.
I understand the point of multiple threads and locations not being "timed", but if the package was able to be fit with an "A" sleeve when leaving the factory floor, any gun with an "A" sleeve would all be able to have the sleeve changed to the next sleeve once the barrels ran out of adjusting notches.
I am only thinking of the common starting point, not the actual pre-fit work to make them all reach that starting point. I am sure you already understand all of this, anyway.
This next part is not a comprehensive history lesson, just comments of interest.
The barrel takedown for these guns was still a bit of an upgrade, compared to the original takedown lever rifles, since they used screws in the frame face that were backed out to remove thread play: basically an adjustable (one-sided) shim.
The next upgrade was the Remington 17 (IIRC), later to be reincarnated into the similar Ithaca 37, where the nut at the end of the mag. tube was "extended" to tension the barrel. I believe it was the Remington 31 that had the first mass production barrels that could be interchanged without fitting, when looking at threaded barrel attachment versions, and that didn't have the front end of the gun hanging on the barrel section.
Most shooters have seen the tongue-n-groove barrel/frames of the Savage/Stevens 520/620 as another version of swap-barrel takedowns (a few of them required minor fitting to swap). Those were probably the most common mass-production guns with the swap barrel feature from the early era, with lesser amounts of the old Marlins of blow-out bolt fame.
These old-timers all had the front half of the gun as a removable assembly, like 97's and M-12's.
The Winchesters and Savage copies (1921/28) were the ones with a fixed rim edge i.e. chamber ring. All the others had the headspace vary with the barrel/thread fit wear. Winchester decided to not do that with the .410 Model 42.
Anybody ever get to see the Model 12 .410, serial #8? I saw that at the Tulsa show, long ago, and that thing was built on a 12 gauge frame. The barrel tapering down to a skinny section from that fat breech made an unusual sight to behold.
kirbythegunsmith@hotmail.com