I couldn't find plastic plugs for the safety hole, so I tried a pair of 1/4" inch Nickel-Plated Steel Hole Plugs (4th pic). The one on the right side worked okay after I used another hammer to pound the 8 ounce ball peen hammer into the hole and caved it in. It was nice and smooth and concave. I had to bend the prongs out farther and I used a gloss black paint pen to paint it. The one on the left side wouldn't fit well no matter how I hit it with a hammer and punch. I tried flattening it out except for the part that curved up at the back, but it looked like crap no matter what I did. I used a larger chrome-plated version of these steel plugs when the sprayer on my kitchen sink started leaking. I clamped the hose off, took out the "collar" that the spray wand stood in, and popped a steel plug in the hole. They work great for things like that. The roll mark on the right side of the receiver says, "1894-1994" like (I think) all M94s made in '94 did.
I tried something like a Chicago screw or bookbinding stud. It was too large in diameter so I ground, filed, and sanded it until it fit. The screw was too short, so I got a longer one longer one and cut it to length. The shaft was
way too thick (that's what my ex said
) and the hammer wouldn't drop, so I cut it down shorter to move it back out of the hammer's path. But then there weren't enough threads for the screw to catch on. So I took the hollow, threaded part I cut off and put a short screw in one end and the long screw in the other. I installed it in the gun and the hammer still wouldn't drop with a #10 size screw blocking its path. I don't know how other people could get a 1/4" Chicago screw running through there to work when the safety needs a clearance notch half its diameter for the hammer to clear it.
I decided the best thing to do was cut the end off the cross-bolt safety and re-install it. Last week, instead of using the padded jaws and clamping everything except the end of the safety in the vise, I tried clamping just the very end in the vise without the padded jaws. The jaws don't line up perfectly and the safety turned on an angle and flew across the basement when I tightened the vise. I still haven't found the safety so I ordered a new one. I cut the end off, ground, filed, sanded, and blued it. It's not perfectly flush with the safety off, but only sticks out 1/64" or something I can't measure. If I press it in with my finger, it moves a little bit and pops back in place. I can put the safety on if I use a punch of something to push it in. But I wanted to eliminate it. I circled it in yellow in the 3rd pic. The saddle ring used to be screwed in where the red circle is. I took it out and plugged the hole years ago. It's always been scarred up from the stud screwing up against the side.
I'm done working on this one unless I mount a red dot on it. I thought about buying a Red Dot Mount for Winchester Model 94 and 1892 Barrels from Turnbull Restoration on it, and mounting a Burris FastFire 4. But I can't remember the last time I shot it, so iron sights are good enough. It would be a good option to have in my tent in case Yogi or Boo-Boo stop in, but it gets really humid in there and it would have to be wet with oil to avoid rusting. My aluminum/chrome-plated and stainless steel pistols fare well enough most of the time.
https://www.turnbullrestoration.com/gun/dovetail-red-dot-mount-vortex-venom-burris-fastfire-winchester-94-1892-barrel/ https://www.burrisoptics.com/red-dots/fastfire-4
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