I just received a new Deerstalker .54 via mailorder. Nice looking rifle, just what I was looking for. However, I'm unable to get the barrel key to fit, it's misaligned by about one thickness of the key on the left side.

I was able to improve the situation a little by putting a shim under the breach, but the key still won't go fully through the left side, off by about 1/2 a key thickness.

I can return the rifle for an exchange, however I'm thinking by bending (arching) the barrel key in the middle a little, it could then probably be fully inserted through the left side of the stock. However, once I do that, I've bought this particular rifle.

Anybody else have this issue, the supplier said this fit issue has been a problem with Deerstalkers, but most folks get it resolved, but didn't specify how.

Any thoughts would be appreciated.

I used to build Hawken rifles, what I did to fit them if they were a little off was use a chisel with the sides milled flat if I needed a bit extra space and use a pin punch on the loop if it needed to be tighter.I made a set of these of slightly different thickness as different guns grouped better with different pressure on the wedge.
While I have no doubt that bending the wedge would work I would not recommend it as any slight movement of the key from barrel whip or recoil is liable to change the POI.

The "key" on my Lyman DS has a slight bend in it. But it came from the factory that way. I never ever gave it any thought until you just mentioned it. There are some experts here who will give you the perfect advice. But I have never had a problem with mine. But I will admit that the key is very very snug. But the rifle shoots great?? Tom.

Thanks for the replies. There is plenty of room in the loop for the wedge, actually there's probably 1/16" of an inch or more extra space. The barrel just doesn't sit down quite far enough in the stock to allow the wedge or key to align properly to hit the left side hole in the stock.

I tried removing the forearm cap to make sure there wasn't a fit issue there, no change.

I suppose if the loop was opened up just a touch to lower the bottom part of the loop, that would allow the wedge to pass through more straight in this case. Just hate to do that much tweaking on a new rifle...... Arching the wedge itself would be a little simpler.

The wedges in my great plains rifle have a very slight arch to them, that gun shoots great, and I would expect the same from a deerstalker.