Hello!
I am certain many here have had their share of trigger guard breakage during cleaning take down and reassembly. Also, the frustration that the trigger guard is plastic rather than a robust metal construction. The available metal trigger guard assembly is almost as expensive as the rifle itself and most of us are either of limited funds or have a bit of Scottish heritage financially.
After replacing two original trigger guards with nothing but pieces left after the second take down I analyzed the two failure modes. The first failure mode comes from tightening the rear screw and is only avoided by not applying any real tightening torque to the rear screw. The second failure mode occurs at the two extremely thin sections at the back of the magazine well with breakage occurring when the guard is bound up in the stock when trying to disassemble.
The first repair methodology involved chemically welding the parts together using acetone applied to the clean break sections and bringing the components together. The initial bond is established within a few minutes and then the parts should cure over night to ensure maximum strength. This repair methodology is effective for the first failure mode with good longevity to the repair and a clean repair. However, this methodology is inadequate for the second failure mode as the component strength of the original design is substandard to begin with.
The second failure mode requires a repair methodology that will increase the cross-sectional area at the two sides of the rear magazine well. The material of the trigger guard is injection molded ABS plastic that acetone is a very effective solvent for allowing a chemical welding bond of the surfaces of the breakage provided the breaks are crisp and clean. However, acetone will not build up the cross-section at the rear magazine well. After considering the desired result of increasing the component cross-section and strength, I experimented with Medium Black ABS Cement (Oately, Plumbing Dept.). The cement bonds and cures fairly quickly and is of a consistency that allows build up of the cross-section. After application and building the cross-section up and curing over night, I filed and sanded the clearance surfaces for mounting and magazine clearance creating a significant increase in the vertical cross-section and making the original trigger guard very strong and resilient. I recommend using throw away hobby artist paint brushes for the cement application. It can take several applications to build the cross-sectional area.
The repaired trigger guards function flawlessly and cost about $7.00 for enough material to repair several hundred trigger guards.
Hope this is useful to someone.
Cheers!
I love the Marlin 795, though I agree that the original trigger guard is fragile and poorly engineered. It is also annoying that the only alternative seems to be the aluminum ones at roughly $60 each. I'd rather sped that money on tech sights. I wonder if there is a way to make replacements on a 3D printer. If so, then the replacements could be designed with more material in the appropriate places, as you described. If anyone has the equipment, I'm sure there would be a ready market here on the forum for a low-cost alternative to the aluminum ones!
I share your frustration. I have two 795's. One with the failures you mentioned. I will say that it took a couple years of hard use before the trigger guard broke. But they did succumb.
I chose the aluminum route. It was $45. Well worth it.
https://www.diproductsinc.com/Products.aspx?CAT=3603 (https://www.diproductsinc.com/Products.aspx?CAT=3603)
Nice job on the DIY fix!
I highly recommend this spring kit:
https://www.mcarbo.com/store/p/26-Marlin-795-Trigger-Spring-Kit-/-Marlin-70-Marlin-995-Trigger-Spring-Kit.aspx (https://www.mcarbo.com/store/p/26-Marlin-795-Trigger-Spring-Kit-/-Marlin-70-Marlin-995-Trigger-Spring-Kit.aspx)
It takes the trigger pull from around 9 pounds down to a bit less than 4.
It's about a 15 minute process and there is no loss in reliablility or safety.
I thought I liked my 795 before, but it's outstanding now.
I'll second the MCarbo Springs.
After I had already replaced the springs, eventually my trigger guard also broke. I replaced it with the DIProducts version (thanks again for the reference, NJRefugee). Since I was already ordering from them, I also got their target trigger.
All told, that trigger now runs around 2.75 lbs with minimal pre- or over-travel. It's niiiiiiice. ..:..
Mcarbo talks about Appleseed.
http://www.mcarbo.com/marlin-60-vs-marlin-795-which-of-these-classic-rifles-is-the-best.aspx