The devil's in the details. Try something new. Make us proud.
Don't tempt me.
I already have a real hard time following plans to the detail. I tend to get an overall feel of how something works, then make it the way I see best. I'm also lazy. So cutting out M or K baffles doesn't really appeal to me, though I'd do it if I knew for sure that they'd be better. Cutting M baffles, or cones and spacers, doesn't appeal to me because I feel I could just stamp/form them easier and lighter, though possibly with less precision. I still like the crimp idea for the blast baffle, though now I'm worried I might torque the tube while trying to apply the crimp. So here's what I like currently:
Threaded muzzle end: Normal,...maybe skeletonized for more volume. Welded on. I just went outside and practiced welding on the end of a pipe, and didn't do so bad. Figure I can touch up the weld on the lathe to make it look purty.
End cap: welded on. Only 1/4" thick. EDIT: I changed my mind on this one. It will be another baffle just welded in. I won't form it as much, so it will be mostly flat except near the hole.
Blast baffle: Turned on lathe. Cone shapped. Symetrical.
Main tube and Blast baffle retention: 4130 .095 thick shaved to .065 from both ends, except for 1/8" area 2 inches in from muzzle threads. This will also hold the rest of the baffles together against the end cap. I'm tempted to go lighter on the wall thickness.
Spacers: 1.37" x .035 thick, with a cut in them so that they can be opened slightly for a spring effect, thus fitting tightly to the walls. Spacing will probably be something near .5" or less with 6 to 8 total baffles. Gotta draw it out and see what will fit.
Baffles: Formed from stainless washers that have been trued on the lathe. Forming with a blunt surface, then something sharp like a dead center makes a nice form. The dead center will expand the hole though, so you'd have to start with something much smaller than your caliber. After being formed, they'll be re-drilled at an angle for turbulence.
This all changes by the day, but that's what I'm thinking right now. I'm still tempted to try crimping in that blast baffle. Might have to play with that concept in the near future.