Since it was raining quite heavy,no bow hunting today.
The vent liner in my Triumph worked so good I decided that I would like to have one in my Endeavor as well.
The first thing I found was that the Endeavor BP is considerably harder than the Triumph BP; if you do this project do not turn the drill any faster than 180 RPM and let it feed at its own speed and use a good drill, carbide if you have it.
I mounted the BP in the milling table vise on my drill press and using a #1 drill I line the hole in the BP up with the drill so it was on dead center.
I then took out the #1 drill and mounted a #8 drill and drilled out the touch hole, then I took that out and stepped up to a # 16 drill then stepped up to a # 21 drill. I ran the drill all the way through the seat for the 209, this has proved to have a major effect on reducing the carbon build up under the 209 seat. This is the right size for tapping a 10-32 thread.
then I took a 25/64 drill and inset the end of the BP the distance of 4 threads.
I then mounted the tap in the drill press and took the top belt of the press off; lowered the tap to the breach plug and put about ten pounds of pressure on the handle of the spindle on the drill press turned the top pulley of the drill press by hand until I had 9 complete threads since the Lehigh V liner has 7 and a half threads this is just right.

This is the finished BP after about 45 minutes work. This one was hard enough it took a bit longer. Lee

Looks like fine work to me.

Thank you Tom. I am very happy with the results of the first conversion and so I did not wait for this one to wear down or flame cut. The combination of the larger channel and the Lehigh vent has cut the carbon deposits way back and though it seems to only be a minor difference at 100yds the group is smaller at 200 and beyond I am not sure why as I am using the same load and every thing else. Do you have any idea? Lee

Less carbon in the plug = more consistent ignition and accuracy in a Savage Muzzleloader. I think you are seeing the same thing with your Endeavor. You and Mike did a good job giving people another alternative to buying a new plug.

I agree, with Endeavor BP selling at 44 dollars it is worth doing. I also believe from my experience with the Triumph that a #21 drill makes the optimum size channel. Do you happened to know how the way Mike did it with the threads going on through if I read it right worked out? I was hoping to catch up with him and find out. I know that some times things like that can make a difference. I suspect he had a idea he was checking out. Lee

Lemoyne, How much would you charge to make me one for my Endeavor. Have you shot it yet?

No I have not shot this one yet, but I made one for my Triumph and have been shooting it for some time. Sabotloader is also shooting one his is on an Omega,The design is basically the same. AS for outside work I sold the Muzzle loading and Archery shop some years back and no longer carry insurance. Lee