AR Sponsor
Posted: 1/7/2008 6:31:27 AM EDT
|
... so I picked up one of those cut triangle charging handles that were on the EE a couple of weeks ago; what can I do with it? :-) I've seen them re-welded as a model for new production items, but can a charging handle be re-welded and put to use? Is it a complicated/delicate job, or can I hand a new CH and my triangle half over to any machine shop and say "Here, make whole"? Has anyone done this before with servicable, use-in-a-fireing-rifle results? Thanks in advance, WhyTanFox |
|
I had a friend, he is a welder, re weld one for me. It works fine and looks good. When I got it back it had alot of material built up under the slot. I took a dremel to it and refinished it with norrells and it turned out very good. I have used it alot without any problems. |
Any tips or tricks? Cut the handle square, at angle, or maybe key or dovetail it? I know nothing of welding myself, and will be at the mercy of a local machine shop. -WhyTanFox |
Here's my $.02...  (1) Go to Online Metals and order two of these - 0.625" X 2" ALUMINUM 6061-T6 EXTRUDED RECTANGLE www.onlinemetals.com/merchant.cfm?pid=1176&step=4&showunits=inches&id=997&top_cat=60 (2) Now, ask around among your ARFCOM buddies for one who has one of these in his basement -  www.harborfreight.com/cpi/ctaf/Displayitem.taf?itemnumber=44142 (3) Send your buddy the aluminum stock and the hacked charging handle and ask him to make you one. The stock is already heat-treated to 6061 T6, so no additional treatment is needed. (4) Send the resulting new bare aluminum triangular charging handle to Victor at US Anodizing with instructions on what color you want. (5) Enjoy your new charging handle!  |
Haha good luck with that!!! I thought sizing up the cut Tri-CH, stealing a piece from a current CH, welding together, cleaning up the excess metal, and a little Norells took way longer than it is worth. I can only imagine how long it would take to manufacturer out of a block of aluminum!!!! There are only two economical ways of making that part; one is CNC from a block, and two is cast the CH then clean up in the mill. You would have to have a lot of free time to make these on your manual mill. |
I'm guessing you mean the rounded channel...Well, that's what ball-end mills are for!   The slot in the rear for the latch can be cut with a thin Woodruff keyseat cutter (or even a slitting saw)... Keyseat cutter -  Slitting saw -  (You'll need an arbor with the slitting saw!) It doesn't take any longer than any other hobby...I use a band saw to rough it to size and shape, then bring it down to spec with the mill... To me, the hard part is getting the original part to take measurements from... 
|
I actually sat there and looked at one for about 20 minutes today. Seems like the hard part is not the triangle part, but the front. The hole in the front would have to be drilled to match the channel, and those little nubby things that hold the handle in the rifle would have to be machined...heck, I'm not even sure how I would get the rounded profile on the extreme front of the thing, like I said, I'm new to this machining thing. A little OT, but the other thing I learned today when I tried to machine a mild steel XM177 FH is that it looks like the Chinese ball end-mills I got on eBay by the dozen are literally not going to cut it... |
|
Edwin said "I can only imagine how long it would take to manufacturer out of a block of aluminum!!!! There are only two economical ways of making that part; one is CNC from a block, and two is cast the CH then clean up in the mill. You would have to have a lot of free time to make these on your manual mill." Yup took me about 3 months of spare time to turn out 100 of these complete. It does take time! I started with bar stock 6061 T6 and sheet metal for the latches. A local EDM shop did the work on the latches. When all was said and done I didn't charge enough to pay myself much on these and people still seemed suprised at how much I wanted.  I think if I charged enough to cover all costs and pay myself something like $20 per hour I would need to have charged over $125 for each part. I couldn't see anyone paying that much for a stupid charging handle.
|
I think you have to really like the work if you're going to do it yourself. I like machining and welding. I hate electrical wiring, painting, and plastering.  If I machine a part, whether it's re-profiling a barrel, or making an XM607 stock, it gets done the way I want it. Not the most economical, or quickest, or prettiest way, but my way. I don't mind spending the time to make a part. I enjoy it. Spending more for the tooling than the part costs doesn't bother me. I only make stuff that interests me. Volume production bores me, so I don't do outside work. A charging handle is pretty simple. But I will probably re-machine an A2 CH to look like the old triangular CH's. It's just not that important to me.  ...But I will order a couple blocks of that 6061 T6 aluminum...Just in case I get a weekend off...
|
You might be surprised. Yeah, there would be a lot of bitching, but some would fork over money. |
BIG +1 That's why I'm machining the parts for my 601 clone, anodizing the aluminum parts, and parking the steel ones myself. And I'm way ahead of you on the 6061: 
|
|
Whytanfox, I gave my friend 2 new charging handles and the cut triangle handle. I asked him to cut 1 down and weld it to the cut handle and make sure it is the same total length and the untouched handle. He did it with a straight cut. Using norrells is very easy to do. A bit a research and you can refinish it yourself, or send it out to U.S. anodizing. good luck! |
|
If you can find a competent welder you should be in good shape. Meaning that, if I were you and you're going to pay someone to weld it, find someone with the right equipment and proper knowledge of welding aluminum. Just be sure to give them pretty good instructions. I had one done and it's holding up pretty well. I would have done it myself, but welders and I don't really get along that well. |
Might want to try Speedy Metals for your materials. Speedy Metals Site Good bit cheaper than your link. They'll cut to length for free and they're customer service is excellent. |
Only two dollars cheaper for that piece of aluminum...but then, I'm not machining 100 of them... Here's a couple more links to places I've bought metal/plastics from... www.onlinemetals.com/ www.metalsupermarkets.com/ www.metalsdepot.com/ And my favorite tooling supplier... www.travers.com/ |
Some. But enough? That's a hazard with manufacturing anything. Especially for a limited market like retro AR parts. |
I do TIG welding, and here's something to consider about that...The welding process will obliterate the heat treatment right at the weld itself. The weld may be strong, but the aluminum on either side will no longer be heat treated. Which means those areas will be weaker than any other part of the charging handle. I'm guessing that most here are welding the thin scalloped part, which also has the smallest cross section...and all anodizing should be removed to avoid weld contamination... It may or may not be any big deal; I really don't know what kind of stress is put on the charging handle. Food for thought.
|
Note taken. You bring up a valid point for anyone wishing to take on welding one up. The handle that I have I plan on retiring in the near future
|
AR Sponsor