Is it possible to stake the plunger tube in place securely without any of the staking tools? I guess, is there a way to stake it in place with something else, such as a punch?
Not really.
Thanks. I was hoping to hear otherwise. When I got the parts from my FIL, he told me to get a plain frame, no plunger, no grip bushings... Well, now I'm finding out the hard way that those two things, especially, are a pain to install without the right tools.
A pair of micro/mini vise grips, jaws wrapped with cloth tape. Finger tight to get the alignment and than turned with another pair of pliers; alternated 1/8 turns - worked slow. Only did it once, so I don't know how much of the success was due to luck. Sometimes Murphy gives you one
A local smith/hobbyist suggested (and uses it himself) a drill bit of the appropriate size to fill the plunger tube, and wise grips, along with a small ball bearing to expand (stake) the pins. Sounds like a plan. I'll try it as soon as I have the slide lapped. So far my hands are taking a beating.
It is imperative to support the interior of the tube so it isn't crushed. I think I remember grinding (Dremel tool) a groove in a bit of soft metal to hold the tube against the frame and a center punch from the inside. I may have epoxied it in place first (pre super glue.) The small vise grip and bb or small ball bearing sounds good. But make sure the tube is supported.
If you've got a few 1911's, just buy the tool and do it right. If that's your only one, your local gunsmith can probably get it done in about 10 minutes for about 10 bucks. It's not worth trying to rig a way to do it yourself, it probably won't last even if you do get it staked without damaging the tube, frame, or finish.
The only one I'm working on, for now. If I get it right, I may do more as time and cash allows. Right now it is a nice winter project, although I am quickly finding out that nothing is a drop-in. Well, I called the only real smith in my area and he does not have the staking tool. He now does mostly rifles, has his own cartridge and a switch barrel system, so handguns are not something he really works on. I'm going to use some red Loctite and try staking it with the bb and vise grips. If that doesn't work, I'll peen it with a punch.
A roll pin punch of the proper size does a good job as well.
A pointed punch is a staking tool.
The companies that manufacture tools dedicated to staking plunger tubes do so for a reason.
Before you screw something up that costs you a bunch of money (and some pride too), look into the tool. Brownells has them, and they are only about $35 or so, IIRC. And a pointed punch isn't a staking tool. A staking tool is a staking tool.
The problem with trying to stake a plunger tube using a punch is that there isn't any way to get the punch perpendicular to the inside surface of the frame, so you can't get a symmetrical flaring of the leg. The problem with using plain ViseGrip pliers is that you are almost certain to crush the plunger tube -- even if you stick a drill bit inside. The inside is stepped -- the forward plunger is a smaller diameter than the rear (thumb safety) plunger. Buy the tool.
You can borrow mine. I have the staking tool from Brownells. Haven't used it in a while, will send it to you to use but I want it back. Let me know.
I use the B-Square jig which consists of a steel block with a square groove on one side and a rounded groove on other for supporting appropriate shape tube. The second tool is a 1/4" bar with a sharp pointed staking punch to fit staking pins. Third tool is a tube filler wire which prevents crushing tube. Forth tool is a drill bit which will clean up a slightly bent tube and spot detent on slide stop.