Knight_Operator’s Fully Optioned GSG-522 Build Thread All Mods

**Disclaimer:  BE PREPARED FOR GRATUITOUS AMOUNTS OF HD PICS**
**IF OBNOXIOUS AMOUNTS OF HD PICS CAUSE A GAG REFLEX- PLEASE LEAVE THIS PAGE NOW**


& BOOM ––––- Excel Like a BOSS!

http://i1265.photobucket.com/albums/jj520/Knight_Operator/GSG%20522%20BUILD/GSG522EXCEL.png

B.S. Finance & Economics; Excel is just how I role Brah.

Mods:
Allen Screw Upgrade + Blue Locktight
Hammer Strut Mod
Removed Magazine Safety
Foam Filled Stock
Navy Lower
Custom Washer
GSG-522 to GSG-5 Conversion (not used)
Pinned Advanced Tactical Folding Stock
H&K Take-down Pins
Classic Army RAS (Rail System)
2ng Gen Delrin Buffer Cocking Tube Mod
And a Partridge In a Pear Tree
(holding off on the Firing Pin Mod to observe how the pin strikes)

Shall we begin? Mwahahaha


New Armorers work bench

http://i1265.photobucket.com/albums/jj520/Knight_Operator/GSG%20522%20BUILD/2012-06-24_17-28-08_993.jpg


Brand New GSG-522 *Full Metal Receiver* NEVER FIRED

http://i1265.photobucket.com/albums/jj520/Knight_Operator/GSG%20522%20BUILD/2012-06-24_17-41-02_699.jpg
http://i1265.photobucket.com/albums/jj520/Knight_Operator/GSG%20522%20BUILD/2012-06-24_17-41-13_499.jpg


The Gear (Reference Excel Sheet)

http://i1265.photobucket.com/albums/jj520/Knight_Operator/GSG%20522%20BUILD/2012-06-24_17-34-27_120.jpg


Advance Folding Stock: Pinned with a nut and bolt, blue locktighted.  Folding mechanism was sure to remain completely unharmed.  Fully functional otherwise but cannot be folded; rock solid and sturdy.  CT has an Assault Weapons ban which is fairly complicated and specific in its restrictions. This rifle stands right up to the letter of the law.  Sure to raise a few eyebrows still.

http://i1265.photobucket.com/albums/jj520/Knight_Operator/GSG%20522%20BUILD/2012-06-24_17-35-57_643.jpg
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Foam Filled Original Stock, Modified to accept the H&K Take-down pins.  NOTE: “great Stuff” expanding hardening foam was used for fill.  A 15/64” drill bit is the perfect inside diameter to accommodate the H&K Pins.  Do not use a stone bit like some youtube videos show (its just sloppy and not uniform, your better than that)  It is now ridged, solid, and sturdy that what she said.  ill likely never use it but thats called doing a nice complete job blah blah, Barbra Streisand blah.  Observe:

Cavity

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Foam

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Drilled & Pinned

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Hammer Strut Mod: Thanks to Kilibreaux on Tactical22.net. The main cutting tool was a double cut SF-51 Tungsten Carbide Cutting Bur which I have already used to do a full port and polish on my cylinder head.  This thing is so tough its obnoxious, and it will eat through hard metals with extreme force, it has a tendency for collateral damage, no civilians have been killed during this build.  Don’t stare, it doesn’t like that.  Oil is used to keep the bit cool and metal material wicked away from getting lodged in its burs of death.  Do you think I have a shot at being a hand model??  Ive been told my fingers are fat , Do my fingers look fat holding the dremel?  I digress.  Moving along.

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Le Hammer Strut
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A Cylinder Head port and polish kit was used to smooth out the bludgeoned homicide left behind by the Carbide Bur, a series files were used to finish.  

http://i1265.photobucket.com/albums/jj520/Knight_Operator/GSG%20522%20BUILD/2012-06-24_22-42-39_902.jpg

Reasembly of the Trigger Pack: After the trigger park was GINGERLY reassembled it was vigorously safety checked for function and smooth operation.  Locktighted.

http://i1265.photobucket.com/albums/jj520/Knight_Operator/GSG%20522%20BUILD/2012-06-24_19-20-52_31.jpg

Magazine Safety Removed.  This will allow one to fire the rifle without a magazine being seated.  If you’re wondering- Its nice.

http://i1265.photobucket.com/albums/jj520/Knight_Operator/GSG%20522%20BUILD/2012-06-27_19-06-14_410.jpg


Navy Lower:  The ICS Lower was utilized and let me be the first to say it is more ridgid than the stock lower made by GSG.  Almost twice as much material makes up the walls and its contruction is madeup of hard ABS plastic.  Firstly I went in with a fine tip brush and enamel paint and repainted the letters and dots.  Next I moved onto a dremel cutting disk removing just a c-hair less matiral than I actually needed, test fitting the whole way.  I finished up with an array of sanding disks and specialized files to get a level, smooth, manicured, tight fit of the trigger pack.  Remember you can always remove more material if you need too blah blah, Woodrow Wilson blah.

http://i1265.photobucket.com/albums/jj520/Knight_Operator/GSG%20522%20BUILD/2012-06-27_17-22-46_8.jpg

A series of bits were used to allow the lower to snugly accept the H&K takedown pins (15/64” bit).  I also counter sank the pins.  A ¾” bit was used to allow the safety switch to be installed.  Milling of the Safety Switch was necessary to allow smooth operation.    

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I custom machined a washer (I.E. Grinded the crap out of it until it succumbed to my will), Smoothed the burs, flattened and trued it on an anvil.  I installed it inside the hand grip to give the trigger pack a solid seat in the lower.  Modification of the hand grip cover was as easy as a trip to the grinding wheel of impending doom.  Blue locktighted.  

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Hogue Grip Installation:  Not for the faint of heart nor modest gunsmiths, Engineers or Physicists, easily the most complicated process of the entire build.  I would not undergo this without the advice of an expert.  Serious science techniques and complicated physics nomenclature is preventing me from going into great detail about the installation of this engineering feat.  I will let the picture speak in lieu of science lessons.  

http://i1265.photobucket.com/albums/jj520/Knight_Operator/GSG%20522%20BUILD/2012-06-27_19-03-24_183.jpg

I decided to grind off the serial numbers because I found them to be distasteful and unpleasing to the eye –––––––––––––––––– (jk photoshop - do not do that!)

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Allen Screw Upgrade:  At this point came the full tear down and Allen screw upgrade with locktight.  I had planned to install the GSG-5 conversion kit but after looking over the parts decided that the newer parts on the rifle were better engineered, aesthetically were more appealing, and functionality wise were superior.  The kit was tremendously invaluable for one reason.  The one screw in the entire process that I stripped was naturally one of screws not included in the screw upgrade kit, oh I'm such a silly bitch; not to mention it can’t be ascertained at any hardware store in a 30 mile radius of my dwelling.  Thanks RRAGES.  Luckily the GSG downgrade kit came with a couple extra of the charging handle screws; for GSG Corp invariable knows they suck.   So watch out for those- oh what’s the point it will strip if you even look at it funny, evil little screw.  So forgoing the GSG Downs kit I proceeded to become Rain Man focused on the build and completely neglected to take pictures of the screw upgrade except just this one; I'm sure you can guess how exciting that would have become.   Please file all complaints to the Ellen Degeneres Show.  Initial Lube and Locktighted.

http://i1265.photobucket.com/albums/jj520/Knight_Operator/GSG%20522%20BUILD/2012-06-24_21-09-48_735.jpg
Note:  The enormous blue lighter with a built in light is not necessary for the screw upgrade


The bolt carrier and sub assembly is what is most important about this screw upgrade so be sure sock these down and Locktight them.  Fun Fact #1: lock tight tastes like blue icing; I didn’t know that either.  Don’t do that.  Did you ever hear about the guy who called poison control because he got caulk in his mouth.  Also, it should be known that you WILL need a T9 and T10 torx bit to disassemble the bolt carrier assemble.  good luck finding one (me laughing).

http://i1265.photobucket.com/albums/jj520/Knight_Operator/GSG%20522%20BUILD/troubleshooting1.jpg


Classic Army RAS:  This is the Classic Army RAS we all know and love, always rebranded, but never imitated (rock island, rrages, zairsoft, G&P laser products)  same thing different applications.  I went with the zairsoft (and I believe now is the new rrages) which has bushings and mating surfaces that are specific for the GSG.  BUTTT its not rock solid, there was a but of vertical play, so obviously I had to dismantle it and make it beg for mercy.  I started by flipping the rear bushing just completely around.  Simple enough.  A Little grinding here, some wrenching there and it was nice and tight on the frame.  It actually now seats in the middle of two grooves found just in front of where the barrel meets the upper.  The RAS system is not ROCK SOLID even with the veritcal grip and abuse as a test.  Locktighted and torqued upon reassembly

http://i1265.photobucket.com/albums/jj520/Knight_Operator/GSG%20522%20BUILD/2012-07-05_15-18-48_561.jpg
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Dot Sight: as this is designed to be a full weight CQC tactical trainer I opted for a dot sight.  No magnification is really necessary on these setups and most sights that do magnify obscure the field of view.  This particular model has 4 different retical options, red or green laser, windage/elevation adjustments, and 3 different brightness settings per each .  Obviously I leave it on its green laser setting.  I found that mounting it as close to the eye as possible made for better field of vision and the retical was clearer.  Also the batter last super long.  Left it on all night, twice, and its still going; amazing duration.

http://i1265.photobucket.com/albums/jj520/Knight_Operator/GSG%20522%20BUILD/2012-07-05_16-02-18_893.jpg
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Vertical Grip Tactical Light, Green Laser, High Output Main Light Combo:  First I went through and blue locktighted all of the metal parts that are for the most part permanent.  Then I lock tighted the adjustable switch in place.  Since I am right handed, I positioned the switch to be best actuated with my left hand.  Grip is very comfortable. The green laser is stupid powerful being able to paint a target at the maximum distance I can get a clear shot.  In any condition at night you can clearly see the beam.  The 225 lumens main light is crazy bright, and I have tested it out to 100yrds and it easily does the job.  Pointing it directly at someone is disorienting.  The Tac light is a very low intensity back up light for when you don’t want to signal aircraft.  The best part is the trigger switch.  Letting others handle the rifle they naturally choke down below the trigger never actuating it accidentally.  And yes its comfortable to hold below the trigger.  A downfall of some other grip light systems.  

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This is an image of both the green dot sight (top retical) and the vertical grip laser pointer(bottom right retical) being used in tandem.  The system is sighted in for a longer distance.  this is why the two points do not match up.  

http://i1265.photobucket.com/albums/jj520/Knight_Operator/GSG%20522%20BUILD/2012-07-05_16-10-02_973.jpg

And boom goes the dynamite.
                                               Build Complete!

                                      You had me at TACTICAL <3

Bear in mind: this is a BRAND NEW NEVER FIRED GSG-522!

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http://i1265.photobucket.com/albums/jj520/Knight_Operator/GSG%20522%20BUILD/2012-07-05_16-18-33_461.jpg


Keeping it classy - for all you minimalists out there

http://i1265.photobucket.com/albums/jj520/Knight_Operator/GSG%20522%20BUILD/2012-07-05_16-04-58_200.jpg
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MMMMMHHHHH

http://i1265.photobucket.com/albums/jj520/Knight_Operator/GSG%20522%20BUILD/2012-07-05_16-16-36_831.jpg

Gun porn - I feel so naughty

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This is the Centerfold:

http://i1265.photobucket.com/albums/jj520/Knight_Operator/GSG%20522%20BUILD/2012-07-05_16-24-18_482.jpg


Everything was fine until Mr. Teddy came to power and decided to execute the political dissident Barney for crimes against humanity.

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                                                                                  FIN

Got it a bran new nice dry place to sleep with some friends.  

http://i1265.photobucket.com/albums/jj520/Knight_Operator/GSG%20522%20BUILD/2012-07-16_23-32-06_839.jpg


Sharp friends:

http://i1265.photobucket.com/albums/jj520/Knight_Operator/GSG%20522%20BUILD/2012-07-16_23-34-26_883.jpg

I had originally decided to forgo the upper rail system because the 522 comes with a 6" picatinny rail preinstalled.  upon tearing down the rifle i realized that the rail was actually made of PLASTIC.  which now of course i'm going to have to change.  What do you guys think... flat top extended mount, or just a simple metal 6" replacement?

http://combatoptical.com/images/products/large_599_GSGFTM7.jpg

http://combatoptical.com/images/banner/GSG5FTM_BANNER1.gif


Updated 7/17/12

Also, let me just say that the GSG advanced folding (well not folding anymore) stock is perfect to use in conjunction with the dot sight I added.  I specifically wanted this stock for the adjustable cheek piece.  As any good rifle owner knows, when you put your cheek down on the stock to aim, it should be comfortable and be already adjusted so when you do you are already aiming down sight.  Many snipers know this fact.  See here how the cheek rest runs almost smack into the back of the sight.  makes it a breeze to get an accurate sight picture:

http://i1265.photobucket.com/albums/jj520/Knight_Operator/GSG%20522%20BUILD/2012-07-05_16-04-58_200.jpg

Updated 7/17/12

STATS:

Allen Screw Upgrade + Blue Locktight
Hammer Strut Mod
Removed Magazine Safety
Foam Filled Stock
Navy Lower
Custom Washer
GSG-522 to GSG-5 Conversion (not used)
Pinned Advanced Tactical Folding Stock
H&K Take-down Pins
Classic Army RAS (Rail System)
2ng Gen Delrin Buffer Cocking Tube Mod

Build Time:

Approx 8hrs For Everything

Weight:

10 Lbs

I WANT YOUR OPINIONS!  I was considering painting the logo on the receiver of the rifle (just in front of the magazine well and behind the Classic Army RAS.  Any Thoughts??

looks interesting, nice pics!

thanks.. finally finished.  you posted when i was first building the thread lol

Actually by happenstance yes, funny you should ask, I just graduated with a B.S. in Finance and Economics with a minor.  This build was actually my graduation gift to myself.  I already have 5 other builds drawn up on Excel aswell including one for your 1911 ADOP plinkers.  What kind of position were you looking for?  Shall I PM/Email you my resume?

Updated 7/17/12

Great build! One thing though, in you post you stated that you used a "3/4" bit for the selector switch for the SEF lower. I think you meant 3/8? I might be incorrect though, 3/4 seems big.

Too exciting for me...  I just can't believe you paid that much for a range toy, but to each their own.

I think he wants a cookie!?

Believe it or not it actually is a 3/4" bit.  This is because the selector switch seats in the lower like a turret on a tank.  the shaft that passes through the trigger assemble and into the opposite elector is considerably smaller, and probably 3/8"  but the correct diameter is indeed 3/4 and its a snug fit.

Valid point, but remember, this was my first build,  and first rifle, and im just out of college in a stagnant wage market.  So this is a very fun and inexpensive way to get a ton of range time, cheaply, with a full weight tactical training rifle (its 10lbs).  Moreover I don't ever buy something (except an asset) with the intent to sell it.  So likely i will keep this for life or until it fails me or i die; which ever happens fist.  So that equates to tens of thousands of rounds downrange which is a significant amount of range time.  So at 2.85 cents per round i just picked up 1050 rds for 30 bucks.  Also i must modify everything i have, its just what i do; and many of the parts on the rifle fit a real HK MP5, so when i move to a state that doesn't suck (assault rifle ban), ill be able to transfer many of the parts from my rifle to the HK should i so choose.  Regardless i still saved over $700 off the cost of the build through careful research;  be sure your reading the correct numbers on the excel.

Killer job on the GSG and that spreadsheet... I too am an excel guy so thank you for making me feel like I'm not the only GSG loving excel nut out here... You made my day!

All you need now to complete that badass rifle is the conversion kit to make it look like a real GSG-5/MP5. Email me your address and I'll send you a conversion kit free of charge for you to finish (for now) your project...

Thanks again for making my day!

Julio - [email protected] - I'll confirm it's you when you send me a copy of your spreadsheet...   :)  

Thanks man, i'm glad you enjoyed it.  I appreciate the offer but i actually already have the conversion kit and opted not to install it.  I mentioned my reasoning somewhere in the build.  I would however be interested in one final piece, the extended flat top mount which can be seen here (that ones a freebee) the picatinny rail that came with it is plastic and will likely loose its true.  If you could help me out on that i would definitely send over my spreadsheet.  Its like a super-savers shopping guide to the GSG-522!  PM me if your interested.  Later. K.O.

I really like that stock with the cheek riser. No matter what you spend, as long as your happy with it,that is all that matters. I have done similar things,(not anything like this though,nice job), and  people tell me why would you spend that kind of money. I like different looking firearms and yours is really cool.

Thanks bro,  yea i just did a little write up on the GSG advance folding stock.  Its perfect if you utilize any aftermarket sight and its a 2 position cheek adjustment.  Money well spent i say.  took it to the range for the first time,  needless to say everyone wanted a try.