Hello, I am going to mill out a tank, cannon, type of muzzle brake for my .500 S&W TC encore rifle barrel.

Can you help me with the following:

1. What is the ideal baffle/exit hole diameter? (.020 + groove diameter?)
2. Would it work very well if it is made about 2.5 inches wide and is just one baffle?
3. How many rounds would it last if I made it out of aluminum?

Any other practical tips would be greatly appreciated. This is my first brake.

Thanks, Brian

Tank cannons have not had muzzle brakes since the M48. Ok, the LAV 105 has one, but it is a can with holes in it.
You want an Artillery like, brake.
Look at the Armalite AR-50 brake and copy that.
Yes a 2.5 inch wide brake would be very effective; the physics of it are that you need to direct as much gas rearward as possible. Ideally, you divert as much gas pressure rearward as the projectile and gas pressure is, going forward, Then you get a recoil less rifle. Revolver.
I have fired both the 90 and 106mm RR. Do not stand behind them.
Aluminum? Not sure but gas is fairly cool there.
They sell what you are describing for $25 on that big auction site.

Brakes with more ports, angled back towards the shooter are more effective than a basic 2-port design venting to either side at 90˚ or the cylindrical with a few dozen small ports all the way around.

This guy's test was for 6.5mm type LR steel guns, but the principles are the same. In a .500S&W similar designed brakes will be less effective given the greater mass of the bullet and less powder/gas/pressure available at the muzzle to reduce recoil.

https://precisionrifleblog.com...e-brakes-field-test/

I've used .030-.040 over bullet diameter with no ill effect on accuracy.

Aluminum will last a while, but it will take a beating from unburnt powder impact. I had a 6061 Aluminum brake on a .220 Swift a while back. I kept a reamer handy to clean out the burr that H414 would push into the brake-through-hole. If you are set on using aluminum, use 7075 or other high-strength alloy. It'll last longer. Luckily .500S&W is somewhat self-limiting regarding "volume shooting."

"That big auction site" has lots and lots that could be adapted to work with a .50-cal for very cheap.

dpcd, Thanks for your response. Good info. What Site are you referring to "..on that big auction site."

Thanks, Brian

jpl, Thanks for the good info. The e-brakes field test site is excellent.

As I asked dlcd, what/where is "that big auction site." ?

Thanks, Brian

Haha, rhymes with E-Gay.

Yes, I meant the largest on line auction site on the planet and it does sound a lot as jpl mentions.

Ah-Ha! Ebay! I got it. Thanks boys. Brian