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Grey Haven Arms

Custom Flintlock and Percussion Firearms
Building a Fowler
Knives and Accoutrements
Single Shot Cartridge Gun
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Restocking the Brown Bess

 All our firearms are custom-built to suit our customer's needs and desires; muzzle loading rifles, pistols, and smoothbore arms, flintlock and percussion, right or left-hand. Style, caliber, finish, hardware, sights, barrel, and fit are all determined in discussion with the customer. Each arm will be unique to it's owner. Our guns are original; although influenced and inspired by the old masters, we create arms in our own style, not copies of any existing piece. Relief carving, inlays in mother of pearl, abalone, silver, brass, and wire enhance the appearance of these firearms. We use only the best materials available, and each arm is guaranteed to perform properly. Prices are determined in consultation with the customer.
 Please contact us by phone, mail, or
  Bob Worthington
  PO Box 105
  Greenbank, WA 98253
Scylla, DragonRifle!
Every now and then, the opportunity to expand one's limits and venture outside of the box comes along, Dalienne, my son's sweetheart, afforded me that opportunity, with the creation of a unique half-stock rifle, built to fit, with a dragon theme, oh, yes! A fantasy theme, perhaps, but a real rifle, for sure. The dragon, Scylla, is done with silver & brass wire inlay, her eye is a garnet set in silver. She took a long time to design; Dalienne, Ethan and I all inputting our ideas. The patch box is German silver, set with a jade stone and a ruby. The box is lined with green felt, and contains not patches, but the dragon's hoard of jewels!
The nicely balanced little gun weighs in at about 4 1/2 pounds, and likes to consume 000 buck (.350 ball,) wrapped in Ballistol-lubed pillow ticking, over 30 grains of 3f Goex.

She has a swamped 32", .36 cal. Rayl barrel, "as light as you think safe, Ed;" nice! With Davis set triggers and an HW Robbins lock; an oldie but real goodie from 1972, and a fine piece of maple I've been saving for years, she's made of the best stuff.
Dalienne's long neck and high cheekbones required the use of a Monte Carlo style comb, to give enough drop at the butt with not so much drop at the comb. I incorporated what I consider some of the more special aspects of my previous arms. The off-side panel is a variation of Mike's half-stock rifle (see top of page.) The ramrod pipe risers are also derived from Mike's rifle. The carving at the tang is from the fowler from the "Building a Fowler" page. The hunter's star & oval are oft repeated, as is the toeplate and wire design on the underside of the buttstock, and the hunter's stars for the barrel pins.
With Dalienne's French heritage, there just had to be fleur-des-lis: The pic on the right shows that Robbins lock, too
The cast pewter nose cap, gold muzzle band, the whale tail (actually another fleur-des-lis) front sight and feather finial rear sight are often found on my arms
                                                                                                                      Dalienne takes aim for Scylla's first breath......
And the proof is in the paper! 25 yards, offhand, right out of the box, so to speak! I had only used a bore sight at that point, and she proved to be pretty darn close. Dalienne proceeded to make a nice little group that required just a tinch of leftward adjustment. And I'm so glad she's Team Grey Haven!
                                          Dragon's breath!                                                           One proud Lady, and rightfully so!
Steve's Target Pistol
"If each gun I build isn't an improvement over the last one, then I'm doing something wrong!" Not sure why I put that in quotes; it's my own words. I believe in many ways, this is my best underhammer pistol yet, as it should be. She's a .36 cal. with a 10" barrel, adjustable trigger and modern adjustable rear sight. I think I'm starting to get the hang of these...
She's got the spur-first one in production. Feels really good in the hand. Brown barrel, custom mixed stain. Koa butt cap, flared to firm the grip. 

Steve is from Michigan, so I used his State flower as the inlay motif: the apple blossom.                Below, the sight almost looks as if it belongs there...
Yes, pretty is as pretty does....  That's six shots in a 3/4" on-centers hole, with a "flyer way out there almost an inch away!  (Never mind the .22 cal holes-just practicing.) This was before I adjusted the sights, shot at 25 yards off the bench. Now, I can't wait to see what a real target shooter with good eyes can do!       

JP's Flintlock Pistol
It's taken a couple years, but it is done at last! No copy of any existing pistol, this one is traditionally styled in a contemporary manner, whatever that means! She's a .50 caliber, 10" barrel, with Tiger maple stock, silver furniture, a bison horn nose cap, and Lignum Vitae buttcap. Fire-blued, she also sports a 14K gold ring around the muzzle.

 I wanted to strike a balance between my desire to create a one-of-a-kind special pistol, and my friend's taste for the less adorned. Clean lines and a minimum of inlay and carving on the stock allowed the beauty of the maple to stand on its own, while the fancy barrel gave vent to my desires.


The inscription reads, "For JP Morgan" on the oblique flat, and "by RS Worthington" on the side flat.

                           Above and right, the Lignum Vitae buttcap.

Below, gold, silver, bison and brass adorn the business end.

Below, 25 yards, off the bench, after I shaved about .09" off the rear sight, the first shots fired for a 1-inch group. I'm happy!

The pistol's new home. Jp likes Purpleheart, so that's what the lid is. He's
gonna fill in the leftover spaces with a priming horn and knapping hammer.

Salvadore Dali Gets a Day Job as a Gunsmith!

Meet Salvadore, a project I began a couple years ago and just recently completed. My goal was an ambidextrous offhand target rifle, hence a cheekpiece on both sides of the buttstock. I sometimes experience an eye problem that makes the vision in my right eye unsuitable for shooting, so I wanted a rifle I could shoot equally comfortable left-handed as well as right. Senor Dali's part came with the forearm, which grew from a regulation for a certain match that called for "no detachable palm rests."  The gun shoots a .350 patched round ball, or OOO buckshot with 30 gr. 3f black powder and a pillow ticking patch. Three-shot groups with the Issack Haines style Green Mountain barrel at 50 yards are through the same hole!
The buttstock went through two revisions before arriving at this final configuration

Salvadore Dali's inspiration!                                                                                   And the left side.
                                                                                                                                You can see the splice in the cheekpiece where I raised the profile

The Grey Haven Pocket Rifle
Hot off the press! The latest addition to the Grey Haven line, the Pocket Rifle is a long-barrelled underhammer pistol with a detachable buttstock.  
This one has a fire-blued 16" .36 cal. barrel. Adjustable sights, and a folding front sight help make this baby a little tack driver!




  • The Pocket Rifle can be made with your choice of barrel length and caliber, and choice of finish on wood and metal. Price as shown, $3600.
  • Grip can be custom designed for your hand.                        
  • Your choice of sights.
  • Also available as a Carbine, with a one-piece stock, for $3400.

And the results.... The proof is on the paper!

 Here she is, in pistol mode.

Muzzle loader's tip: (Thanks to Betty Brewer for this one! She learned it from her dad.)
Hat pins, old-fashioned ones, are traditional vent and nipple picks. If you can find 'em, they're period-proper, and handy (just stick one in your hat.)

The First Grey Haven Pistol with a stained grip!
  After the Pocket Rifle, I decided to break my tradition and try a stain on the grip.
I like it! I hope Chad will, too. Y'all are getting to see it before he does! It's a 10" .50 cal.


The adjustable rear sight and a
silver blade front, above.                                                                                   

Chad's Logo graces the right side panel. Note the pivoting safety and
adjustable trigger, right.

My Personal Longrifle
 My favorite; .50 caliber flintlock in the Lehigh Valley style. Top of page right is the              
patchbox of this gun. Below is the cheekpiece.

Toe plate and inlay, below. S-shaped side plate, my standard, at right.


Schuetzen Rifle
   After a year, the schuetzen is ready for the range! .40 cal. underhammer, with a 35"x1" Ed Rayl barrel with a 1:48 twist and Montana Vintage Arms sights, she put the first three shots through the same hole, right out of the box, so to speak. Built for Tom B.; he'll be shooting her at Friendship. May she serve you well, Tom!

The hook, the sight, the palm rest, and oh, that pretty piece of maple!               

False muzzle and front sight. That pin on top keeps you from shooting the false muzzle down range.
 I can attest; it worked three times for me...
                                                                                                                                        Toe plate detail, below.

...And Tom's first target!  Ohh, yeah!

Underhammer pistols


Our only "standard" item,
we make a percussion underhammer target pistol, offered in barrel lengths from 5" to 12", in .32, .36, .40, .45, and .50 caliber. A curly maple grip with a contrasting hardwood buttcap, embellished with mother of pearl, abalone, and wire inlay is standard. Metal and wood finish and sights are the customer's choice. This gun is a proven winner in competition! Price as shown (12" barrel, standard fixed sights): $1300. Target model with adjustable sights and trigger now available for $1500. New pivoting safety is now standard on all models. Also available in a presentation box, either singly or as a pair. We can customize this gun to suit your needs, too.
The unique simplicity of an underhammer pistol, with only four moving parts (trigger, trigger spring, hammer, and trigger guard/mainspring) make it easy to clean and maintain, and provide instant ignition and an uncluttered sight plane. Note the mother of pearl star and the wire inlay "four directions" lines on the butt cap: that is the Grey Haven logo, which you will find somewhere on every firearm we make (Below, left.) Below, right, is a close-up of the robin on my sister's .36 cal. pistol. That's her name; Robin. The bird is Lignum Vitae and Catlinite.

The pistol to the left is number 1, owned by my son, Ethan.

  Bernd's Pistol Passes German Proof Test!
                           The pretty browned .36 cal. pistol below was made for Bernd R. in Germany, and while it was not difficult to ship a muzzle loading pistol to Germany, they do require a proof test before the customer may use the gun. I'm happy to report that the barrel is quite strong, and judging by Bernd's target, is performing well, too! Five shots at 25 meters, offhand (that's a double in the 10 ring.) Nice shooting, Bernd!

A six-pack for six shooters!

Here are the pistols that took
us to victory at the Whidbey Island Rendezvous in 2011!
                                                                                                          Top to bottom:
                                                                                                 8" .45 cal, fire-blued, #5, Alyx's
                                                                                                 8" .36 cal, fire-blued, #9, Robin's
                                                                                                 10" .50 cal, oven-blued, #4 Mine 
                                                                                                 10" .45 cal, browned, #8, Mike's
                                                                                                 12" .50 cal, bright, #1, Ethan's
                                                                                                 12" .50 cal, rust blued, #2, JP's

The Simplicity of the Mechanism
     During the Building process, the action goes together and comes apart
hundreds of times to get everything to work together just right. This is aided
by using long pins to make disassembly quicker. Here you can see the action
in all its glory-not much to hide, after all! This has the adjustable target trigger.

This is the same gun shown above, all done. It belongs to George G. in Germany, and is .36 with 10" barrel and adjustable rear sight, as well as the trigger.
It is one little tack driving pea shooter!  Gonna have to have one for myself...

Mike's Left-handed Half Stock Rifle 

Here's my good friend Mike with his .54 cal. left-hander, to the right. We met up at the 1838 Rendezvous in 2007, and I presented him with this arm. His first shot lobotomized the turkey target! We were both pleased. The barrel is tapered; straight octagon to just past the forearm, with a band, then 16-sided tapering back to octagon at the muzzle, with a twist; the peak is at the top (below.) Above  is the off-side of the breech, showing the long tang. This gun is so sweet; I want one!


                                  Above, the barrel transition.

The cheek piece.
And the off-side of the buttstock.                                                                                                    

Tommy's Silk Purse                                                                                              
   My friend brought me his old kit gun, and said, "I know you can't make a silk     
purse out of a sow's ear, but do what you can." Well, sounded like a challenge to me, so I gave his rifle liposuction and a sex change, and about 300 hours later, Tommy's Silk Purse emerged. Since Tommy built her originally, I put both of our names on the barrel, and added some decoration at the breech (right.) The tang is new; there was this stubby little thing held on with a 1/2" wood screw into 3/8" of wood (stripped out) that the barrel sort of fit into, so it got a real breech plug and tang, through-bolted to the trigger, like it should be. I had to inlet the barrel deeper into the stock, so the drum would seat better in the lock, there would be enough wood around the new tang, and to slim the profile. This required redrilling and pinning the barrel, with resetting or replacing the escutcheons. The barrel had been pinned to the stock by drilling right through the barrel, with no lugs. That got changed! Some trigger and lock work improved her performance. The fore end lost half its wood, and got a new look, with new ramrod pipes and nose cap. Cleaning up the lines and features of the stock and some inlay and engraving added more grace and prettiness, and Lo! a princess emerged where a pig had been! 
Tommy is a Mason and a fellow member of the Cockade Rifles, and his rifle reflects both of these affiliations. Below right, the All-seeing Eye and the inscription on the side plate tell the story.

Even though it's on the "Home" page, I had to show this shot again, since it is the story... Tommy had inlet the patchbox originally. I repaired the spring, engraved it,
and added a little wirework (below.)


The barrel required refinishing after I worked on it, so I decided to use a cold blue that produces a fire blue/case hardened kind of look, which I think goes well with her new image. I reset Tommy's heart inlays, and the star on the cheekpiece after reworking the stock, and reused the forward escutcheons. The rear escutcheons had to be replaced with larger ones to cover up the old holes. Slimmer now, after major nip/tuck and lipo, she got some new hardware and is now the Belle of the Ball! Round ball, that is...

I kept her simple but elegant; I added Tommy's initials to the star, a wire border, new toeplate, reset the buttplate, and the Masonic symbol (below left.)                                                                                                                                                                                                                                                                                                                                                                 

                                                                                                                                                                   Tommy's initials from 1976 are on the lock plate.

The new toe plate, below.

The Fowler
This is the gun on the "Building a Fowler" page. She's 20 guage,
and sweet to handle.

 Although it doesn't have a patchbox or cheekpiece like the Lehigh rifle, the carving and inlay around the trigger guard, lock and side panels, and tang make up the difference. In most other respects, they are a match in design and details. Toeplate, tang, sideplate, escutcheons, stock styling details, use of the feather finial rear sight and fleur-de-lis front (neither of those on this gun, however!), as well as the hunter's star in the oval are some of my trademark styling. Compare these aspects on the half-stock, pistols, and schuetzen, too. And Tommy's Silk Purse has the Four Directions toeplate, as well.

I love the curve of the buttstock and that fiery-grained maple!


                                                                                                                                                                    The rear ramrod pipe with the fleur-des-lis finial.

Dan's Pair
      Here are the boxed pistols I made for Dan and Rita G., in .36 caliber, with 10" barrels.  The pistols are bookmatched, with the same design on opposite sides. The only difference is in the initials, with Dan's pistol above and Rita's below. Rita's gun also has a slightly smaller grip.




Fire-bluing reveals some interesting effects. I like this patch of discoloration! (Above right)

The two sides of Dan's pistol, below.


And Rita's....  The maple grips are bookmatched, as well.


Dan's Rifle
    My next project
for Dan was a .45 caliber underhammer hunting rifle which I just finished on April 25, 2013. With a 36" Colerain straight octagon barrel, it shoots really well, round ball or conical. Hundred yard, three-shot group of 1-5/8" attests to that!

                                                                                                                           Pewter nose cap and buckhorn sight.

Left, I used the same style mini-ribs as I did on Mike's half-stock, in order to save weight.

                                                                                                                                        The safety and the heat-treated trigger guard/spring.

A New Sight for George's New Pistol
    George G. sent me a new adjustable rear sight to use on his second pistol, another 10" .36, and with a little modification, I installed it on his, and made another for a pistol for Raul M. of Arizona. I added a guide to stabilize the sight, as it was a little wobbly without, and now it is really fine. Adjustable for elevation only, windage is done by drifting the front sight. It will now be standard on the target model, as is the pivoting safety.                                                                                   

George's new pistol. A new steel blade is on the front, too.

Left, you can see how the sight mounts on the tang, and how the screw adjustment works. Mounted on the extreme end of the tang, sight radius is maximized.

Right, is Raul's pistol with the new sight. He requested an Arizona Grey Squirrel, so I gave him one in abalone. Kind of a shiny grayish luminous squirrel.... His is an 8" .32 caliber, and shoots very sweetly.

Raul's other side. The fire blue barrel really came out nice, and that maple is striking!

Jerry's Hawken
     My friend and fellow Cockade Rifle, Jerry made this kit Hawken back in the 70's, and recently brought it to me for some embellishment. He did a nice job on it, so there was little improvement for me to make, other than some fine tuning and polishing on the triggers and a little refining of lines. I did some pretty work, but kept it simple to preserve the Hawken essence.

Jerry had done the incised carving around the cap box. I added a little wire
work to accent his line.(Below)

The cheek got a hunter's star and oval with wire embellishment, and a mother-of-pearl bison and Jerry's initials with wire work on the side panel, Right.

Just a simple line around the lock to accent the line.

A Spanish Pistol Repair
My neighbor purchased this Spanish pistol at auction, and asked me to repair a broken mainspring on the back lock. I had to make my own mainspring vise, more like pliers really, to do the job. I found a generic mainspring through Dixie Gun Works, and modified it to fit. Below, the pliers, the lock with new spring installed, and the old broken spring.
 A well-made piece, wood to metal fit is nice, and engraving on the lock and gold-filled engraving on the barrel, "Por Gastelu" and the date, "Ano 1866"         

Mickey's Colt Replica
Friend Jerry brought me his cousin Mickey's rather rough Colt 1851 Navy replica, put together from a kit. Basically, nothing worked, and the barrel was jammed on  the cylinder pin. First job was getting the barrel off! That took some file work and finagling, some sanding & polishing and adjustment of pin fit, and that worked. Next, the hand pushed the cylinder too far, so a little sanding and polishing solved that. The half-cock needed some filing to open up the slot enough to work. The cylinder stop required bending, sanding, and heat treating before it would function properly, along with some work on the hammer; filing, sanding, & polishing. It also required a new spring, which also required some adjustment. Timing wasn't bad, and a little file work evened that up nicely. The sight wasn't there, so I made one from 1/8" brass rod. Sanding and evening up the metal parts, polishing the brass, and refinishing the grip took care of the rest. I am still awaiting the arrival of a new barrel wedge,  but I made the old one work for the test shoot. The photo speaks for itself! Not bad for a 15 yard group, 1 3/4" on centers! Actually, it is two groups of three, as I fired the first three, and my son Ethan fired the second three-his group was better than mine, but still, mine was only 1 3/8" on centers. Not too shabby for a short little puppy! (PS; the wedge came in while we were at the range...)