Jeff,
The other thing I do when preferring to go "traditional" with iron-sighted rifles, rather than using a fiber-optic front, is using a very fine, small file to put a 45-degree angle on the surface of white or brass beads--angling "away" from the shooter. This not only picks up more light from the sky in dim conditions than a round bead (or even a flat-faced bead that directly faces the shooter) but eliminates "hot spots" on the side of the bead.
It sounds like you're attempting to rerecreat the old Redfield "sourdough partridge" style front sight.
