Re: recontouring finished fluted barrel
I've seen it done, and I've had to do it myself. Not with a fluted barrel, but a similar L/D ratio with 5 interrupted "flutes" on the outside.
The job took a long time, the parts we were working on had to be "made to work" and it was actually going to be more expensive to make new than it was to make these work... but not by much.
Barrels do not cost mid-4 figures for blanks. The best way that we could do the job was actually to set it up in an absolutely massive swiss machine and run it through there to get the grooves out, leaving about 0.020" on the OD to clean up. <span style="font-style: italic">(ETA: The reason the clean up material was left is because the swiss didn't have the travel to cut the whole thing, so the part was flipped midway and it needed a single continuous cut).</span>
We then put them in an NC turning center with 80" between centers, ran a follower rest and parameterized the diameter every 1/2" along the shafts.
It took many hours and like I mentioned above, it was expensive but not quite as expensive as getting the material and cutting it from scratch.
Bottom line: Yes it can be done. I sincerely doubt it is cost effective vs. just buying another tube in order to really get it done right.