By Paul Evancoe

The explosive bonding process has been understood for most of the last century being first observed as a result of warfare. Metal fragments from exploded artillery shells and bombs were observed to bond with other metal objects in the close proximity of the explosion. While the root cause of this phenomena was understood, it’s metallurgical and commercial value was not explored until high explosives were perfected and mass produced during World War II making the explosive bonding process reliable and cost effective. Even then, it was only patented and further developed during the 1960s.

The process involves using high explosives to accelerate two metal plates together at a velocity sufficiently high enough (millions of pounds of pressure) to achieve metallurgical bonding at the atomic level. As sophisticated as this might seem it really isn’t rocket science. Two metal plates to be combined must have clean flat surfaces where they are to be joined. The plates are laid flat in direct contact with one another on an anvil and high explosives are placed on top, evenly covering the plates. Any high explosive will work, e.g., C-4, TNT, Detasheet, even ammonium nitrate if boosted. The explosives are detonated creating the bonded metal plate. The resulting transition joint (weld) is ultra-high vacuum tight giving it high mechanical strength.

This means metals as dissimilar as 6061 aluminum and 304 stainless steel can be metallurgically joined creating bi-metal billets from which the stainless steel is utilized for wear surfaces and the lighter more malleable aluminum for other non-wear surfaces. This makes it ideal for firearms construction because it can withstand drastic thermal and pressure excursions without separation.

The advantage of using explosively bonded metal in firearms construction is because it achieves significant weight savings without sacrificing the resilience and performance characteristics of steel. Neither is there the need for exotic and expensive machining processes used for metals like titanium. Therefore, explosively bonded metal can be machined without the expensive process of special handling or retooling.

The U.S. Army acts as the soldier weapons executive agent for all branches of the U.S. Armed Forces and heads the Program Executive Office – Soldier (PEO Soldier). The number one goal for all future soldier-carried equipment is to reduce the soldier’s load. In other words, make everything lighter and easier to carry. Weight reduction in pistols, assault rifles and machine guns is a worthy goal. However, light construction most always results in reduced reliability and weapon life span. Lightweight weapons made from lightweight materials simply wear out faster than heavier weapons made from heavier materials, especially when continuously exposed to rigorous combat extremes. In short, mass matters. Guns made from explosively bonded metal appear to provide a solution. We decided to find out by operationally testing two explosively bonded prototype model 1911 .45 ACP pistols manufactured by UA Arms.

The size of the explosively bonded billets necessary to build a 1911 frame is 7x5x1inches. Approximately 3/8 of an inch of 304 stainless is bonded to a 6061 aluminum slab. When machined, the stainless is used for the wear surfaces. A rough order of magnitude cost comparison of explosively bonded billets compared to conventional steel and exotic titanium are as follows: The average cost to build a conventional 1911 cast steel frame is about $150 dollars. The average cost to build a frame from a forged steel billet is around $200 dollars. The average cost to build a frame from an explosively bonded billet is $350 dollars. The cost to build a titanium frame is around $475 dollars. Compared to a steel frame, the weight saving in the explosively bonded frame is quite remarkable depending on materials used and model. Conventional all steel 1911’s average 44-46 ounces. UA guns with explosively bonded frames and slides average between 25 and 28 ounces, depending on the model.

The Operational Test Plan (OTP) was designed to test the viability of using explosively bonded dissimilar metals in firearm construction. In this case, 6061 aluminum was explosively bonded to 304 stainless steel. The advantage of using this process is firearm weight reduction without sacrificing reliability, maintainability and availability. Reliability refers to the proper functioning of the gun. Maintainability refers to how easily the gun is maintained and how often maintenance is necessary both routine and repair. Availability is a factor of reliability (failure rate) and maintainability (parts availability, interchangeability, how quickly can it be repaired and back in service) between malfunctions and breakage. Simply, availability means that the gun is in an available status when you need to use it and not broken, malfunctioning or down for repair.

The 1911 .45 ACP was selected because its performance is so well (understood) known and documented over the last 100 years. UA Arms machined ten 1911 frames with integral rails from explosively bonded billets produced by Pacific Aerospace & Electronics (PA&E). UA Arms has exclusive distribution rights from PA&E to use its explosively bonded billets in firearms construction.

Two of these ten pistols, serial #004 and #008, were randomly selected for operational testing. UA Arms custom built these pistols for close quarter battle (CQB). Both guns were ceramic coated inside and out to reduce bi-metal electrolysis and corrosion when immersed in a saltwater environment and to provide a self-lubricious coating to meet the Navy SEAL and Marine Corps special operations requirement to reliably fire a minimum of 200 rounds immediately upon exiting from prolonged water submersion without lubrication.

While testing was not focused upon match-grade accuracy, Uselton installed front blade Novak combat front night sights and Novak rear adjustable combat sights on both guns at the Operational Test Director’s (OTD) request. Novak sights were chosen because they are literally bomb proof tried, tested and proven and there was no need to test the sights, just the guns. Five 8-round blackened stainless magazines by Act-Mags were provided with each gun from UA Arms. Ten additional Novak 8-round blackened stainless magazines nearly identical to the Act-Mags were provided by the OTD.

The Operational Test Plan was designed to operationally test the two weapons using scenarios that realistically represent combat conditions and environments. Only 230 grain ball ammunition was used in the testing, which was derived from a variety of manufacturers that included Winchester, Wolf, PMC and Remington. Ammunition brand was not considered in the testing and was utilized without preference. Gun magazines were mixed among the two guns and not dedicated to a specific pistol.

Prior to turning the guns over to the Operational Test Director (OTD), UA Arms conducted a technical test with Serials #1004 and #1008 under fall-season outdoor dry range conditions. Each gun was fired 300 rounds by UA Arms on their factory range with no reported malfunctions prior to sending them to the OTD. The guns were cleaned, lubricated and shipped to the OTD in like new condition. Please note that rounds fired outside the control of the OTD and this OPEVAL (Operational Evaluation) are not factored into the evaluation data. They are only mentioned for the purpose of gun legacy.

Operational Test Plan

An Operational Test Plan was developed by the Operational Test Director. It was never shared or discussed with UA Arms or anyone else. The OTP consisted of 6 phases of testing. It was designed so that the phases would not need to be conducted in a particular linear sequence. Each pistol was equally tested to the same limits and fired the same number of rounds.

Of note during the testing, all gun maintenance and cleaning was done under field conditions. Lubricants used were WD-40 and CRC Industrial 3-36. All reference to tactical shooting means the guns were always fired outdoors at steel and/or paper pie plates at various ranges for center of mass hits. The guns were never fired on a controlled distance range, either indoors or outdoors, aiming at bull’s-eye scored targets. The following describes each phase of testing.

Phase 1: Tropical Environment 100 Rounds

The Operational Test Director began the test regimen with experienced SWAT team officers shooting on an outdoor tactical range. The guns were fired holding them in the vertical up, down, side and level positions. Because of the 1911’s design, shooting it vertically (up and down) in itself can many times cause feed malfunctions and the OTD suspected that there could be an issue since the pistols were approximately 34% lighter than a traditional all steel 1911.

Within the first 96 rounds fired through Serial #1008 there were five feed malfunctions. The round was getting jammed between the frame’s feed ramp and the barrel feed ramp. There appeared to be an excessive gap between the two. When releasing the locked-back slide (using the release lever to close the slide after reloading) there were also three slide malfunctions where the slide would not carry the next round fully forward and return in battery. Additionally, the slide did not cycle properly during shooting all of which was attributed to a weak recoil spring. Most attention getting, the all-aluminum grip safety failed to work at all. This was attributed to excessive wear from UA Arms’ previous technical testing.

Within the first 80 rounds fired through Serial #1004 there were eight failure to properly feed malfunctions. Like serial #1008, the feed ramp was suspect as was the recoil spring. This gun also had a slide release lever that was too tight to allow easy slide release using one thumb. And, like serial #1008, the grip safety didn’t work for the same reason.

At this point the OTD made the decision to return both guns to UA Arms for the fixes. UA Arms replaced the recoil springs with heavier springs that provided positive slide return/closure. They also polished the lower and upper feed ramps on both guns. To cut weight, Uselton had originally equipped both guns with aluminum grip safety levers that were too soft to withstand the wear from technical testing. Both grip safety levers were replaced with conventional steel levers and the problem was eliminated. UA Arms again test fired each gun an additional 300 rounds on his own range. The guns were returned to the OTD in 6 days in a like new condition and the OPEVAL was resumed. As these fixes were minor not requiring factory (depot level) maintenance, it is important to note that the OTD could have affected these fixes on his own if he had chosen to do so. Rather, outside of the OTP, he chose to test UA Arms’ factory repair turn around which proved excellent.

Phase 2: Winter Environment 400 Rounds

Both guns were lightly lubricated at 28F ambient then fired 100 rounds each on the OTD’s West Virginia tactical range without experiencing malfunction. The guns were again lubricated (not cleaned) and each loaded (rounds chambered and placed on full cock with thumb safeties engaged). They were laid on a wooden platform and fully exposed to a freezing winter environment that included periodic snow and freezing rain for a period of two weeks. Without cleaning, additional lubrication or warming, each was fired an additional 50 rounds without malfunction.

At this point the guns were cleaned in the field and closely inspected for rust, corrosion and any sign of failure of the aluminum and stainless bond. Neither gun showed any deterioration.

The next part of this phase involved fresh water and mud submersion. Both guns were loaded, hammer back, thumb safety engaged and submerged about a foot deep in a flowing freshwater West Virginia mountain brook, resting flat on a mud/sand bottom. After four hours the guns were retrieved and immediately each fired 200 rounds on a tactical range. Serial #1004 experienced a stovepipe feed malfunction on its 8th round. The jam was immediately cleared, the gun was reloaded and it shot the remaining 192 rounds without failure. Serial #1008 shot flawlessly.

The guns were cleaned in the field and lubricated, then loaded (hammer back and thumb safety engaged) and again submerged about one foot deep in the flowing stream only this time they were pushed down into the mud and covered. After 4 hours the guns were retrieved and quickly rinsed off in the stream by running them back and forth through the flowing water to wash the surface mud off the slide and frame. Both guns were then each fired 50 rounds without malfunction.

Phase 3: Temperate Environment 500 Rounds

The guns were each exposed to a demanding 500-round regimen of tactical range shooting from all positions and attitudes (vertical up and down, horizontal conventional, side and upside down. Both guns along with all their magazines were cleaned in the field and lubricated every 100 rounds. No malfunctions were experienced.

Phase 4: Maritime Environment 200 Rounds

In this phase of testing both guns were each exposed to seawater for 4 hours. The guns were lubricated and placed in a mesh nylon laundry sack that was suspended beneath a pier at a depth of 10 feet. Because of the location available for this test the guns could not be loaded with chambered rounds but loaded magazines were installed. Following the 4 hour exposure the guns were retrieved and fired 200 rounds each without lubrication using the tactical regimen referenced previously. Both guns performed flawlessly.

Following this the guns were both rinsed off with fresh water, cleaned in the field, lubricated and closely inspected for rust, corrosion and any sign of failure of the aluminum and stainless bond. Neither gun showed any deterioration.

Phase 5: Desert Environment 240 Rounds

The Operational Test Director was limited in this test phase because of the physical location and the lack of availability to an actual desert environment. Simulating a desert environment was attempted by open carrying the guns in a nylon mesh sack during lengthy sand dune walks in the Virginia capes. Granted, the sand in some deserts, depending upon their location, more resembles fine powder rather than granular sand. This limitation to testing could not be simulated without actual exposure to that particular desert location. The next best simulation was to expose the guns to blown sand.

Following exposure to windblown sand for 30 minutes, both guns were loaded (round chambered with thumb safety engaged), placed in an oven and heated to 130F for 4 hours. The guns were removed and immediately each fired 80 rounds. This sand-heat-shoot cycle was repeated three times with the guns being cleaned in the field, lubricated and closely inspected for any sign of the aluminum and stainless bond after each 80 round cycle. Serial #1008 experienced a failure to feed malfunction on its 4th shot. The slide didn’t quite return to full battery. After being rapped with the palm of the hand it closed fully and fired flawlessly during the remainder of this test phase. Serial #1004 failed to feed on its 82nd shot and like its sister gun, it didn’t fully return to battery. The unspent round was manually ejected with a snap of the slide and the gun continued to fire flawlessly.

Phase 6: Drop Testing 60 Rounds

Drop testing is usually done at the start of testing. Because these pistols were unique, the OTD made the decision to conduct potential destructive testing last. Both guns were cleaned, lubricated, and loaded (round chambered, thumb safety engaged), then dropped from a height of 6 feet onto a hard concrete pad. For safety, the guns were suspended above by their trigger guards and remotely released. Once on the concrete pad, they were retrieved and each fired 20 rounds. The drop test was then repeated twice again as was the firing cycle. Both guns fired flawlessly.

The guns were cleaned in the field, inspected for drop damage, and any sign of failure of the aluminum and stainless bond. Outside of some minor superficial gun finish bruising, neither gun showed any component damage or bond deterioration.

Conclusions

• Test data reflects that the UA Arms 1911 .45 ACP CQB is a reliable combat pistol.
• Explosively bonded aluminum and stainless construction in this pistol makes it approximately 34% lighter than its steel counterpart while exhibiting superior ruggedness, wear resistance, reliability, maintainability and availability.
• Because of the gun’s lighter weight, it cycles much faster.
• The UA Arms explosively bonded 1911 CQB does not require attentive maintenance and possesses superior aversion to corrosion, rust, and internal part seizure.
• CQB variant’s weight and the feel of its action (form, fit, function) provides quicker sight acquisition when engaging multiple targets.
• Because of its aluminum-stainless construction, it possesses a very low magnetic signature when compared to a conventional 1911.
• Internal parts are completely interchangeable with conventional 1911s and they can be mixed as required.
• Training and use is identical to conventional 1911s.
• By nature of the 1911’s design and operation it generally is not fitted with a sound suppressor as the additional weight on the barrel results in failure to eject and feed depending upon the gun’s vertical up/down attitude when firing. While not part of this test, the Operational Test Director believes the UA Arms explosively bonded 1911 CQB may possess the ability to function reliably with a barrel-mounted sound suppressor perhaps also manufactured from bonded material.
• Based upon the results of this testing, the OTD unconditionally endorses the use of explosively bonded materials in the manufacture of all firearms from pistols to machine guns.

(About the Operational Test Director (OTD): Mr. Evancoe is a retired Navy SEAL. During that time he served as an OTD for the SEAL Weapons System during assignment to the Commander, Operational Test and Evaluation Force. Following retirement from the Navy he served as the Director for Special Operations at the Office of the Coordinator for Counterterrorism at the U.S. Department of State, Director of the Office of Emergency Response at the National Nuclear Security Agency, Vice President for Military Operations at FNH USA, president of Aegis Industries, and Liaison Team Lead for inter-agency explosives technology subject matter experts at DHS Science and Technology Directorate’s Explosives Division. He is also the author of three military action novels; Own the Night, Violent Peace and Poison Promise).

By Frank Iannamico

AK Photographs Courtesy of the U.S. Marine Corps National Museum

Shortly after World War II began, the belligerents involved soon discovered that they needed to increase production of weapons to arm their expanding armies and replace those arms damaged or lost in the field. The problem they all faced were the lack of machine tools and men to operate them. There was also a shortage of the raw materials needed to fabricate weapons, with the aircraft and ship building factories having priority. The solution to the problem was first solved by the Germans who pioneered an entirely new method of manufacturing small arms using inexpensive carbon steel stampings, assembled with rivets and welding.

The most successful German weapons fabricated from sheet metal were the MP40 submachine gun and the MG42 machine gun. The ordnance establishments of the world took notice and soon introduced their own sheet-metal weapons. The British had their Sten, the United States M3 and M3A1 “grease guns” and the Soviets fielded their PPSh and PPS43 submachine guns. Despite having a rather crude appearance, the sheet metal weapons were proven to be every bit as rugged and reliable as their labor-intensive counterparts.

Every gun designer studies previous designs to learn what works and what doesn’t. Mikhail Kalashnikov was particularly impressed with the simple, all-metal stamped steel construction of the 7.62x25mm Pistolet Pulemet Sudayeva, PPS43. Kalashnikov realized the pressed steel construction was the way future small arms would be made. Three basic principles would be followed in all of Kalashnikov’s designs: simple, reliable, and easily manufactured. Accuracy requirements in the Warsaw Pact, though important, were not as critical as the requirements of the NATO member countries.

The very first production AK rifles were manufactured with stamped sheet metal receivers before the more commonly known milled receiver model appeared. There was no designation change regardless of the receiver type; they were simply called Avtomat Kalashnikova rifles. The designations Type 1, Type 2 and Type 3 have been widely accepted by historians and enthusiasts as a means in which to identify particular AK models. However, these are not official nomenclatures. Despite numerous detail differences, there was no designation change to any AK rifles until the AKM model was introduced in 1959.

The First Generation Russian AK

Although there were a substantial number of prototypes and experimental versions of the AK rifle, the very first production models emerged during 1948 from the Izhevsk Motor Plant, factory 524. Other armament plants supplied some of the parts and components for assembly of the weapon. During 1949, production was transferred to the Izhmash factory 74. (Dan’s note: General Kalashnikov was in Serbia at the Zastava factory at Kragujevac, and he was out to dinner with three of us Americans- weapons designer Charlie Rostocil, Dr. Philip H. Dater of Gemtech, and myself. Charlie kept on the subject of “The first AK,” because the General had always held that his first model worked, and was the “First AK.” Finally, the General admitted there were 5 or 6 prototypes, but “The first AK was the one that worked perfectly, the others were just attempts.”

The first production AK rifles, chambered for the intermediate-range 7.62x39mm cartridge, were produced with receivers fabricated from a 1.3mm thick U shaped sheet metal stamping. Located at the front of the receiver was a machined block of steel that served as the barrel trunnion. The trunnion was secured in place by eight rivets; four on each side of the receiver. The inside of the trunnion block was threaded for attaching the barrel to the receiver assembly. This also included locking shoulders for the breech bolt, short sections of the bolt guide rails and the ejector. A second steel block was positioned just forward of the barrel’s breech. This component housed the rear sight assembly, had a flange for the gas tube, and the components for locking the gas tube in place. The lower part of the block encircled the barrel and had a lateral solid steel cross pin installed to prevent the rear sight base and barrel from loosening.

At the back end of the receiver was another steel trunnion that had two tangs extending from it to secure the buttstock, and a groove at the top to contain the guide rod of the recoil spring assembly. This piece was secured with three long rivets, which extended completely through both sides of the receiver.

A similar assembly, without the extended buttstock tangs, was used for the underfolding stock model. All of these components served as “bulkheads” providing the sheet metal receiver with strength and rigidity. The upper edges of the sheet metal receiver were bent inward at a 90-degree angle, providing rails for the bolt carrier to ride on. Two additional bolt guide rails were riveted to the inside of the receiver, just forward of the trigger guard. A horizontal rib pressed into each side of the receiver at the top that served as a ledge to support the receiver top cover and add strength to the receiver. The top cover was smooth and made of heavy gauge stamped steel that was 1.6mm thick (.063-inches).

On the underside of the receiver was a stamped steel trigger guard assembly. At the front of the trigger guard was a channel to house the magazine catch and spring; at the rear of the trigger guard was a long sheet metal tab that extended down from the receiver for attaching the pistol grip. The pistol grip of the first production model was unique in that it had two wooden or plastic side panels secured by a lateral screw and threaded insert. The trigger guard frame assembly was attached to the receiver floor by five rivets.

The fire control components were held in place and rotated on steel axis pins placed laterally through the sides of the receiver. The pins were secured in place by the long trip sear spring, which rested in grooves located on the left end of the axis pin-heads. The double-hook trigger, hammer, and disconnector were a design that was similar to those used on the later milled receiver AK rifles. The rod of the gas piston had flutes machined into its shaft to reduce its weight and the gas piston assembly was chromium-plated to resist the effects of corrosive ammunition. The bolt carrier and bolt were left in the white. The sheet metal steel gas tube ribs had four round gas relief holes placed horizontally along the length of the tube on each side at the 3 o’clock and 9 o’clock positions. The recoil spring assembly had two telescoping hollow metal tubes. The spring was installed over the tubes and was secured by a steel circular retainer cap that was slotted. With the spring compressed, the cap was slid onto a groove cut into the front guide rod holding the assembly together. The mode of fire-safety lever had only one tang located at the lower edge. The tang was bent at a 90-degree angle and served as grip surface for the operator’s fingers to move the lever. On the inside surface of the lever was a small dimple designed to position the lever in one of two small, shallow circular depressions drilled into the receiver. The depressions were used to retain the lever in the semiautomatic or full-automatic position. On some early guns, the semiautomatic and automatic fire positions were not marked. Provisions for a cleaning rod were located under the barrel. The hardwood stock was secured to the receiver with two wood screws – one placed through each of the steel tangs of the rear receiver trunnion. A flat steel buttplate was positioned at the rear of the stock and secured by two wood screws. A trap door was provided to access a hole drilled into the rear of the stock for storage of a cleaning kit. A sling swivel was located on the bottom of the stock a few inches forward of the buttplate. The loaded weight of the Type 1 rifle with early “slabside” magazine was 10.13-pounds (4.60kg). The overall length was 34.375-inches.

AKS Rifle

To fulfill the requirement of a compact weapon for issue to paratroopers and vehicle crews, a variant was conceived with a folding stock to reduce the overall length for storage or transport. The weapon was designated as the AKS rifle. The letter S for Sklodnoy (a Cyrillic letter C) was added to the designation to indicate that the rifle had a folding stock. The AKS models were fitted with a steel folding stock, which required a special rear trunnion to accommodate its locking mechanism. The trunnion was riveted into place at the rear of the receiver. There were two large 16mm holes provided on each side of the receiver walls to accommodate the pivot pin for the stock to rotate on. The design of the steel underfolding stock was similar to that used on the World War II German MP38 and MP40 submachine guns. The stock’s two strut arms were made from round steel bar stock with lightening cuts milled out of the inside surfaces of each of the arms. The stamped metal skeleton buttplate was attached to the end of the strut arms with two rivets that allowed it to swivel for extending the stock or folding it for storage under the receiver. Early prototype buttplates were an enclosed oval shape, but on production rifles, the buttplate was redesigned with an open top so the stock could be folded with a magazine in the rifle. To release the lock mechanism to fold or extend the stock, there was a checkered push-button on the left side of the pivot pin. With its folding stock extended, the length of the AKS rifle was slightly longer at 34.5-inches than a fixed stock model when measured to the center point of the curved buttplate. The loaded weight was also slightly more than the fixed stock version at 10.26-pounds (4.65kg). Other features were the same as the full stock model.

While the stamped sheet metal AK receiver had proven to be suitably durable during the extensive trials and testing of the weapon prior to adoption, the technology necessary for mass-producing such a receiver proved to be lacking. There have been many conflicting accounts of exactly why the Russians went from the original stamped Type 1 receiver to the milled Type 2. Typically, the Soviets did not divulge a lot of information, especially regarding a design failure. Two of the reported problems experienced early on with Kalashnikov’s Type 1 AK rifle were receiver strength and accuracy. One could surmise that the problem was that the trunnion was not adequately supported in the receiver. Years later, the stamped receiver AKM suffered from similar accuracy problems, which were eventually solved through the addition of the hammer delay system. Other accounts report that it was difficult to hold manufacturing tolerances due to warping of the receiver after riveting and heat-treating.

There have been a number of Type 1 AK and AKS rifles studied by the author, all were fully serviceable, with no signs of any structural failures observed.

During the 1950s, the only viable solution to the Type 1 receiver problem was to switch to a receiver manufactured by the previous, and well-known, method of machining the component from a steel forging. Using this old but proven procedure resulted in slower, more expensive production. While the new milled receiver was being designed, and subsequently manufactured, production of the AK rifles with the stamped steel receivers continued at Izhmash until being phased out around 1951, at which time rifle production was switched completely over to the Type 2 forged/milled receiver. The Soviets have sometimes noted that the Type 2 milled receiver weapon was the “new lightweight model,” but in reality its weight was 6.34 ounces (.18kg) heavier than a Type 1.

(Article excerpted in part from the book AK-47 The Grim Reaper Available from Chipotle Publishing LLC. Telephone: 702-565-0746. www.smallarmsreview.com)

By Christopher R. Bartocci

Black Hills Ammunition (BHA) is one of the most recognized names in the industry for premium quality ammunition for hunting, self defense, law enforcement and military customers. The true niche for Black Hills’ products is custom, precision and high quality ammunition. The biggest customer for BHA is the U.S. military. They manufacture perhaps the most regarded and well known 5.56mm cartridge, the Mk262 Mod1, in use by SOCOM. Black Hills Ammunition manufactures several other custom combat loads for various other U.S. military units. The quality of BHA is second to none; they do not compete in most orders requiring the lowest bid. They have extreme pride in their quality of ammunition and are not willing to take away the man hours of inspections of components and final ammunition to compete in low bids. They have no desire to be known as the low bid/low quality manufacturer. However, this keeps them out of the law enforcement market due to the fact that almost all law enforcement contracts go out for bid. Generally due to budget restraints, the main concern is cost and over-all reliability. The military on the other hand has the opposite view on ammunition. They have exceedingly high standards and are willing to pay for the best ammunition in the world. They also have many different missions requiring specific needs. This is where BHA comes in. There are no engineers at BHA as they are an assembly plant not a design firm. When Jeff Hoffman is presented with a requirement, he seeks out the proper components. If those components don’t exist, he works with his suppliers (who he has more than 20-year relationships with) to custom design and manufacture that projectile or powder blend needed for that particular requirement. These close relationships with ammunition component manufacturers to develop new and improved products have made Black Hills Ammunition one of the highest quality manufacturers of ammunition in the world.

Small Arms Review was granted a rare inside look at the Black Hills Ammunition manufacturing plant in Rapid City, South Dakota. We were taken from the R&D labs right into the production and quality control areas. The facility was converted from a dairy plant and was well suited for the needs of BHA. There is a main manufacturing plant along with an additional storage facility and primer and powder storage containers that all conform to U.S. Department of Defense (DOD) regulations for storage of powder and primers. Like any U.S. DoD contracting location, security is very strict with many levels of restricted access areas. Not to be unheeded, the front door is guarded by a large overlooking gargoyle.

The first stop on the tour was the warehouse. The warehouse was loaded with projectiles of all sorts, primers and large caches of cartridge cases. The military production components are kept separate from the commercial. BHA purchases as much components as possible when they become available and will store them. In the last couple of years ammunition components have become quite scarce. BHA is an ammunition manufacturing facility and without components their loading machines sit idle. Every effort is made to keep enough stock so the chances of production being halted due to running out of components is left at a minimum.

The second place Jeff Hoffman showed was one of the two ballistic laboratories used in the development and testing of ammunition. Proof barrels are installed in the main unit. Pressures, velocity and various environmental conditions can be tested. The test barrel is fired through three tires, then through three sky screens that capture velocity and the projectile is captured in a snail trap. These systems may be used for development of new products or to test various lots of ammunition to ensure it conforms to the specifications. There are two ballistic labs; one for commercial and one for military ammunition.

Next we were shown the Gel Room. This is a dedicated room for mixing and preparing ordnance gel in testing all types of ammunition. There are two large refrigerator units that are always filled with gel. There are various length molds as well. This is a critical testing procedure, particularly when manufacturing military ammunition. The gel also will give immediate feedback if the projectiles will maintain their weight or fragment as well as a very good visual regarding the permanent cavity damage the projectile will make.

Due to Black Hills Ammunition manufacturing ammunition for military use, every effort is made to ensure the ammunition is combat reliable and as absolutely uniform lot to lot as is humanly possible. They have a humidity environmental chamber that is used to condition reference ammunition to assure the most accurate results possible in referencing Black Hills Pressure test barrels.

Quality control starts with each and every component. When your reputation depends on the performance of the ammunition, BHA does not take the word of their vendors that everything is within specification. BHA offers two different types of ammunition, new and factory reloads. In the case of the reloads, brass is accepted from sources which BHA is sure they are only once fired. Each fired cartridge case is visually inspected for serious scratches, damaged rims, bent mouths or any other anomaly that may make the cartridge case speculative of performance in a reloaded cartridge. New cartridge cases are inspected at the loading machine. Depending on the type of cartridge case, they may require priming or in the case of military ammunition, the cartridge cases may already be primed and have the primer pocket crimped. In the case of the primed cartridge cases, the loading machine operator will hand inspect each round prior to it going into the hopper of the loading machine. The slightest blemish on military contract ammunition will be rejected. One of the more common manufacturing defects noted will be the lack of uniformity or a missing flash hole. The new unprimed cartridge cases go through the same process but the additional step of priming is added to the assembly process.

Primers go through inspection as well and there is a separate room where the primers are examined. Each primer is inspected to assure all three components are present (cup, anvil, firing mixture). Mostly Winchester primers are used exclusively by BHA. On very rare occasion a primer will have one or all of the components missing or the primer is assembled incorrectly. Although a very tedious process, this quality control measure guarantees to the extent possible, that the round will fire when struck by the firing pin. Once the primers are accepted, they are fed into a machine that loads the primer tubes (100 each) that are fed into the loading machines.

Bullets are also inspected. Due to the degree of accuracy required, projectiles are inspected and weighed to make sure they conform to the specification. Depending on the projectile type, they are checked to make sure that cores are complete and uniform. BHA uses numerous manufacturers of projectiles including Hornady, Sierra and Barnes to name a few as well as cast lead projectiles. Depending on the order, the projectile is procured. Much research and development is done on behalf of customers to find projectiles to meet a specific requirement. BHA will find that projectile and if it is not available they will work with the manufacturer to design and manufacture it for that customer.

Propellants are another very critical component in the cartridge performance. Depending on the particular caliber, projectile weight and cartridge case, there are numerous propellants that may be used. The military has different requirements than a hunter. They will need flash retardants for nighttime firing. Some propellants burn faster and some slower. Modern propellants now can increase the performance of older calibers by the improved propellants that give similar or better performance with less volume of propellant. Military weapons offer their own set of challenges where propellants are concerned due to the need of both a certain chamber pressure but also a certain port pressure. Depending on the location of the gas port and the distance from the gas port to the muzzle, various propellants may be needed to control the pressure curve so as not to over or under pressure the operating system. As new requirements come up, BHA research and development people work with the powder manufacturers to design proper blends to accomplish the task at hand. The propellant used in the Mk262 Mod1 is a custom blended propellant just used in that cartridge.

The loading rooms are split into two different ones – one for military production and the other for commercial production. This is done for several reasons, with one of the most important being storage of proper components where they are to be used.

By industry standards, the BHA loading machines are quite slow, though that is just fine with Jeff Hoffman. The type of detail the machine operators must have could not be done as well with high volume machines. The operators are normally assigned to one loading machine. This is for several reasons; the most important is that the operator knows the machine completely. The operator can tell by the sound or feel if something is just not right. The operator is responsible for keeping the hoppers full of projectile, powder and cartridge cases and in other cases primers as well. However, at the same time they are inspecting every cartridge case that goes into the hopper and when the loaded cartridge comes out the loading machine. The cartridge is tested with calipers for overall length as well as chamber gauge. Throughout the day, one of the four managers goes to each machine, pull cartridges, inspects the powder charge, quality and lengths of the cartridges to ensure everything is right. There are also cartridge gauges that are inserted into the loading machine to check all the settings. There is a rigorous inspection of the loading machines to ensure the best product is being produced.

The loading machines are totally automatic with the operator just feeding in the components. In the case of military ammunition, the decapping and priming steps are skipped due to the cartridge case already having the primer seated and crimped. Some of the stations of the military production include length die, slight flaring of the mouth die, charging, dropping of the projectile into the mouth of the cartridge case, seating and crimping of the projectile.

After the cartridges are assembled and inspected, they go to the tumbling room. There are several tumblers with corn cob media to clean any contaminants or fingerprints off of the cartridges ensuring against corrosion of the cartridge. From this point on, the cartridges are handled with cotton gloves. Depending on the customer, most cartridges are left in for only a brief time so the annealing marks are not removed as per military specifications. In the case of commercial ammunition, these are often polished out. Once the ammunition is cleaned it is ready to be inspected one more time.

Also depending on the customer needs, some military ammunition is subjected to an additional primer and mouth sealant. This $300,000 machine is quite interesting. The cartridges are laid on a track. The first position, a needle located right on the cannelure drops some red sealant onto the cannelure at the mouth of the cartridge case. As the cartridge rolls on the track the sealant is evenly and lightly distributed around the full circumference of the projectile. The next stage is another needle that places sealant between the edge of the primer and the primer pocket. Again as the cartridge rolls on the track the sealant is evenly distributed around the circumference of the primer. The next stop is the cartridges are run under a UV light that instantly cures/dries the sealant. This process is unlike the standard Lake City Army Ammunition Plant sealing process. When you examine closely, the Lake City brass has purple sealant on the primer that often makes its way onto the face of the primer. The BHA process does not. It sits perfectly in the edges. On the Lake City ammunition, you see a black tar like mouth sealant and on the BHA it is a perfect round ring that will not affect accuracy or reliability. This process does add cost to each cartridge and is reserved for military customers whose ammunition will be exposed to the harsh environment that could kill a cartridge if left unsealed.

The next step is final inspection and packaging. This time an inspector with a fluorescently lit magnifying lens inspects each cartridge for any cosmetic blemish, e.g., a tool mark/scratch, dent or staining. If something is found the cartridge is removed and placed in a “seconds” bin. The seconds are sold as fully functional ammunition but with minor cosmetic flaws. Often this ammunition can go to manufacturers as function test ammunition or may be sold on the commercial market. In the case of pistol ammunition, the ammunition is placed in a tray that holds 50 rounds. There is a block placed over the rounds and the tray is flipped allowing the inspector to view each cartridge tip, then flipped over the base of the cartridge allowing for inspection of the primer. Everything is good, a packaging ammo box is placed on top, the tray is flipped and now the ammunition is ready to be slid into a box. One final quality check to go. The box of ammunition is placed on a scale which knows the exact weight that box is suppose to be. Even the slightest difference flags the inspector. This could indicate the lack of powder, or a defective projectile to name a few things. The box will then be removed and each round inspected until the problem is found.

Now the ammunition is placed into the box and then packaged into a case. The case is stapled, banded and ready to be shipped to the customer. Military ammunition goes on a different path after inspection. Depending on the contract, the ammunition may be placed in a 20-round box or the ammunition must be placed on stripper clips and three stripper clips placed in a box. The contract stipulates packaging, which usually consists of the ammunition being placed in an ammo can, two cans make a wooden crate and the crate sealed with metal wire. Ammunition for the U.S. military is picked up by the military in their own trucks unlike other ammunition finding its way out UPS or Fed Ex. If requested, ammunition can be manufactured in lots using the same lot components (cartridge case, primer, propellant and projectile). For instance, with match ammunition being used in competition or by snipers, they do not want to have to change the dope on their scopes to compensate for a different lot of ammunition. They are able to procure large lots of the exact same production ammunition.

There is essentially no inventory of ammunition at BHA as ammunition is made to order. As fast as it comes off the production line it is out the door to many different types of customers. One niche BHA enjoys is they are the largest supplier in the industry of proof ammunition for gun manufacturers. This ammunition is purposely loaded to 20% over normal pressure. Gun manufacturers use this ammunition at the factory to test new firearms to ensure the proof round does not damage the gun. The theory is that if the high pressure round is fired, any metal failure will present itself. All goes well and the weapon is not damaged the guns are shipped. In the case of military weapon manufacturers, often following a proof round being fired the barrel and bolt are inspected by means of magnetic particle inspection to see it there are any stress fractures. These proof rounds are manufactured for both rifles and pistols. Often they are identified by their silver colored cartridge case or in some cases the projectile is painted. Many different types of projectiles can be loaded in a proof round, it just has to conform to the proper projectile weight and it must not come apart when fired.

Black Hills Ammunition provides function test ammunition to numerous foreign and domestic firearms manufacturers. Any quality gun manufacturer will test fire their firearm for function and accuracy prior to shipping. This is often where the factory seconds will go but new manufactured ammunition is procured as well. This is another example of the trust the industry puts in Jeff and Kristie Hoffman’s hands.

The military ammunition is the largest part of the business as previously stated. BHA has been on the forefront with the development of several cartridges in use by American Warfighters. This includes the SOCOM Mk262 Mod1, the MK255 Mod1 as well as many custom loads for various military/government units. Jeff Hoffman’s expertise has led to advancements in the quality and performance of the 7.62x51mm M118LR PIP ammunition as well as advancements in .300 Winchester Magnum and .338 Lapua Magnum loads. BHA is also the manufacturer and co-designer of the ammunition used in the U.S. Army Marksmanship Unit, Air Force Marksmanship Unit as well as the Marine Corps Marksmanship Unit. BHA has some international military customers as well. These customers are more than often units who worked closely with U.S. Special Operations forces and saw the ammunition they had and decided they wanted the same ammunition. They would contact BHA and as long as all the export paperwork was in order they will ship to the foreign customers. This is and will remain the core of BHA business and center of focus.

Remanufactured ammunition is a good part of the Black Hills Ammunition lineup. They offer numerous .223 Rem loads as well as the .40 caliber pistol loads. The once fired brass is procured from agencies BHA works with and knows the ammunition was once fired. According to Jeff Hoffman, with the degree of quality control in the manufacturing process there is literally no performance sacrifice due to the once fired brass with the only real differences being a few scratches and an extractor and ejector mark that are just cosmetic. The remanufactured ammunition is packaged in blue boxes.

The newly manufactured ammunition is also offered in multiple calibers, for both rifle and handgun. Identified by the red boxes, this ammunition is manufactured with new cartridge cases: mostly Winchester and Lake City cartridge cases. Calibers offered are the basic military calibers including .223 Remington, 5.56x45mm, .300 Whisper/Blackout, .308 Winchester, .300 Winchester Magnum, .338 Lapua and .338 Norma Magnum. There are numerous types of bullets including Varmint Grenade, Hornady V-Max, Match Hollow Point, Full Metal Jacket, Soft Point, Barnes MPG, Heavy Match Hollow Point, Hornady and Sierra MatchKing OTM/JHPBT, solid Barnes and Hornady solid copper G-Max/TAC-TX projectiles to just name a few. Much of this is match grade ammunition used for long range and competitive shooting. One of the most popular products is the 5.56mm 77grain OTM ammunition, which is a commercial version of the highly sought after Mk262 Mod1 ammunition. Once word got out regarding the performance of the military ammunition there was a large request from customers for the same ammunition. Normally, it is the exact same ammunition. Recently due to a little explosion in the propellant plant that makes the specific propellant for the military load, newer lots of commercial ammunition use a slightly different powder than the military load. The ammunition has identical performance. Once production resumes to full capacity of the propellant manufacturer, the propellant will be universal. Like any government contractor, U.S. military contracts come first.

The Black Hills Gold line of ammunition are comprised of various commonly used hunting cartridges including .22-250, .243 Win, .25-06, .260 Rem, .270 Win, .30-06, .308, .300 Win Magnum and 7mm Rem Mag. The loads consist of hunting projectiles Varmint Grenade, A-Max, V-Max, Hornady SST, Hornady GMX, Barnes TSX, Hornady Match Hollow Point, and Nosler AccuBond. These are projectiles intended to hunt any game in the continental United States. Some of these projectiles are also used in competition shooting as well. This ammunition is packed in the yellow and black boxes.

To round out the family of products is the Authentic Cowboy Action ammunition. Cowboy action has been an ever growing shooting sport. Gun manufacturers have brought back the older single action revolvers and lever action rifles. There are also those who compete with original production firearms as well. With this demand Black Hills Ammunition introduced 13 calibers of traditional cowboy ammunition to their lineup. All loaded with lead projectiles/flat tip, the cartridges are designed so they can be used in many original production firearms. However, if you have an older firearm it is best to have it examined by a competent gunsmith to ensure it is safe to fire. These cartridges include .32 H&R, .32-20, .38 Long Colt, .38 Special, .38-40, .38-55, .44 Colt, .44 Russian, .44 Special, .44-40, .45 Colt, .45 Schofield and .45-70.

Black Hills Ammunition manufactures precision high performance ammunition. The degree of quality and precision does come with a price. With the very prestigious list of customers who use BHA products, including the most elite soldiers in the U.S. military, the reputation of Black Hills Ammunition is well established. If you are looking for inexpensive plinking ammunition, perhaps this is not your brand. But if you need to hit a 1,000 yard target, stop a Taliban in his tracks, shoot competition, need self defense ammunition or custom ammunition, Black Hills Ammunition is your place to call.

By John Brown

Changes in Leadership

During the last several months we have noticed many changes occurring within the leadership of ATF. The first announcement was the news that Arthur Herbert, Deputy Director, would be retiring at the end of 2014. That news had been heard before and we had our trepidations about that being true. However, it is official that Mr. Herbert is retiring and will be leaving after a long career in the Bureau. Candidly, our work with Mr. Herbert had not been met with the kind of cooperation that we had hoped. However, with patience, things eventually change. We just hope that the change is not worse than what we had.

As mentioned in an earlier article, many of us in the industry have noted some positive small changes in cooperation while working silently behind closed doors with those ATF personnel still friendly to the industry and who have been steadfast in their work with us. Now, in recent meetings both official and unofficial, it is a far cry from the days in this administration when ATF personnel were blatantly told not to even accept a bottle of water from industry members. Many of the cooperating personnel within ATF simply shrank back in the shadows and waited for things to change. Patience has its virtues and things are starting to pay off.

Early in the summer Marvin Richardson, soon to be Deputy Director, held a manufacturers meeting in Washington D.C. It was the first time in a very long time that all of the ATF staff and major industry members came together and genuinely smiled at one another. Credit goes to Mr. Richardson for pulling everyone together and discussing a multitude of regulatory issues that affect us all and all participants walked away from that meeting hoping for better times in cooperation.

Though we knew what was coming, we enjoyed much cooperation from ATF during this administration’s first term. It was of course in the second term that the storm started to brew and rain down a ton of anti-firearms legislation, targeted at manufacturers as well as the consumer. We have seen plenty of this during the first year and a half of the second term. Under White House direction it is no secret that the Justice Department has taken apart every idea from the industry and turned it against the consumer and the manufacturer. A simple idea of streamlining the Form 4 processes, by eliminating the Chief Law Enforcement signature, has turned into an absolute nightmare. The fear is that the more time that falls behind this type of legislation the less likely its impact.

Although the Justice Department has seen fit to forge its way into virtually every type of gun legislation, mid-term elections and dissatisfaction with the current administration are once again allowing a strong spirit of cooperation between ATF and the industry and consumers. A single example of this resides in the doubling of the staff tasked with processing forms for all types of NFA articles. Now at 9-10 months, with a target of six months, the Bureau in responding cooperatively with all of the trade associations and the consumers by adding appropriate staff to handle the load that is unprecedented in the history of the NFA. With a backlog of nearly 45,000 forms monthly at the NFA Branch, increasing staff is a natural and cooperative move to assist the consumer and the industry.

Changes in leadership at ATF will help at the Federal level and will once again give us the spirit of cooperation that we had enjoyed for so many years. With Marvin Richardson moving up, the dominoes start to fall and openings for more leadership positions will occur. Keeping a good relationship with ATF has always been a dictum of the NFATCA, and these changes will fuel our hopes of continued cooperation. That posture alone has been the reason why the NFATCA has enjoyed more cooperation from ATF than any other trade association in the firearms industry. We have stood steadfast for nearly twelve years and have withstood pain and agony of many types of proposed legislations. We have worked hard to support the industry and the consumer and have published the NFA Handbook and are nearly complete with the publication of the Firearms Technology Handbook. We will continue to keep our membership apprised of the latest news on all fronts.

The changes that we are seeing within ATF leadership are very positive. We have a lot of ground to recover and many things to yet accomplish. With a strong leadership within ATF and strong leadership within the NFATCA, we can and will accomplish our goals for the future.

Come join the NFATCA today and become a member of a powerful team that works for you, the industry, the consumer, and the sportsman, in defending not only our Second Amendment rights but for your NFA rights nationwide.

By Robert M. Hausman

Synopsis of Annual Imports Conference

The following is a synopsis of the 13th annual Importer Licensee Conference held by the F.A.I.R. Trade Group (an importer’s industry organization) and the National Shooting Sports Foundation in Washington, D.C. in August. This was the 13th year of the conference, which was attended by about 150 persons.

ATF Panel

The opening panel was from the Bureau of Alcohol, Tobacco, Firearms and Explosives (ATF), the agency responsible for administering the import provisions of the Federal firearms laws. Alphonso Hughes, Chief of the Firearms and Explosives Services Division, announced a number of staffing changes, including recent hires to assist in processing import applications and National Firearms Act documents. Chief Hughes announced a goal of reducing the current processing time for tax-paid NFA forms (Forms 1 and 4) from 9 months to 6 months.

Desiree Dickinson, Imports Industry Liaison, discussed the mismatch between terms of validity for ATF’s import permit (2 years) and the International Import Certificate (IIC), which is 6 months. Dickinson advised that the Department of Commerce, which has ownership of the IIC, will soon extend the term of validity to 1 year. She suggested that industry members discuss extension of the IIC to 2 years with Commerce.

Dickinson reviewed the changes made to the U.S. Munitions Imports List (USMIL) by an ATF final rule published in March, 2014 (rule can be accessed at www.gpo.gov/fdsys/pkg/FR-2014-03-27/pdf/2014-06778.pdf). The rule removed a number of categories from the USMIL as part of the Administration’s export control reform initiative.

William Majors, Chief of the Imports Branch, emphasized the staffing challenges presented by the increasing volume of import licenses. Majors made it clear ATF will entertain requests to expedite import applications only with documentation the articles sought for importation are required for a law enforcement agency or other government agency.

Lee Alston-Williams, a senior specialist from the Firearms and Explosives Services Division, gave an update on ATF’s e-Forms. Due to problems with the current software, ATF has removed a number of NFA forms from the e-Forms system. Alston-Williams stated the system currently supports the Form 6 import application, Form 6A, Release and Receipt of Imported Firearms, and the ATF Form 1, Application to Make and Register a Firearm. ATF is working with a new e-Forms contractor and hopes to provide the firearms industry with new and improved e-Forms in the future.

The final speaker on the ATF panel was Helen Koppe, Chief of the Firearms Industry Programs Division. This Division is responsible for marking variances for firearms, which are generally processed within 90 days. Koppe announced that the responsibility for responding to marking variance requests will be transferred to the Firearms Technology Branch in the Fall 2014.

During the question and answer session, a question was raised about publication of the final rule relating to the notice of proposed rulemaking on NFA trusts (ATF 41P, published in the Federal Register September 9, 2013, (www.gpo.gov/fdsys/pkg/FR-2013-09-09/pdf/2013-21661.pdf). Andrew Lange, Chief of ATF’s Regulations Division, stated that the large quantity of public comments may delay publication of the final rule until 2015.

Alphonso Hughes answered a question about possible suspension of permits authorizing import of firearms and ammunition from Russia. Chief Hughes announced that all permits would remain valid until the Department of State directs otherwise. He stated that ATF would process all new applications for permits unless the application lists a party blocked by the Office of Foreign Assets Control (i.e., Kalashnikov Concern).

Automated Export System

Joe Cortez of the Census Bureau’s Trade Division gave an update on the Automated Export System (AES). Cortez outlined recent changes made to the Foreign Trade Regulations and the data elements added to the system by those changes.

United Nations Arms Trade Treaty

Bill Kullman, Deputy Chief of ATF’s International Affairs office, and Rick Patterson, Executive Director of the Sporting Arms Ammunition Manufacturers Institute (SAAMI), gave a presentation on the United Nations Arms Trade Treaty.

Kullman emphasized the role of the United States as raising the small arms import and export requirements of the world to the “gold standard” of the United States and to avoid committing the U.S. to additional unnecessary requirements. Patterson stated that the firearms industry should be concerned about the treaty’s lack of definitions for terms including “small arms,” “ammunition,” and “stockpiles.” He said these omissions are deliberate and provide a placeholder for future amendments that could be detrimental to legitimate commerce in firearms. Patterson also mentioned end-use certificates and more burdensome transshipment requirements as potential problem areas in the treaty.

Round-Table Sessions a Big Hit

Sponsors of the conference made a major change in format by devoting most of the afternoon of the first day to round-table discussions. Ten different tables were set up with government experts ready to discuss imports, National Firearms Act transactions, Firearms Industry Programs issues, ATF e-Forms, ATF field compliance inspections, Immigration and Customs Enforcement, firearms and ammunition excise tax (Treasury’s Tax and Trade Bureau), Automated Export System (Census Bureau), State Department Licensing and Policy, and sanctions imposed by Treasury’s Office of Foreign Assets Control. The smaller groups and informal discussions resulted in many lively interchanges between government experts and industry members. Experts and attendees said the format resulted in great communication and should be continued.

ICE Emphasizes Criminal Smuggling Violations

The final session for Day 1 was from David Whalen of Immigration and Customs Enforcement (ICE), Homeland Security Investigations (HSI). Mr. Whalen’s experience investigating cross-border firearms smuggling was evident as he gave attendees examples of “red flags” that should raise suspicion in international import and export transactions. He assured attendees that HSI is interested in investigating egregious criminal violations, rather than technical regulatory violations.

Add-On Session for Basic Import/Exports Training

Based on feedback from previous conferences, F.A.I.R. and NSSF offered attendees an optional 2-hour basic course on importation and exportation. Approximately 60 attendees signed up for the course, many new to import/export. Teresa Ficaretta, a Federal retiree with 28 years of ATF experience, gave the imports section of the training, which included an overview of the import provisions of the Gun Control Act, the National Firearms Act, and the Arms Export Control Act. Jim Bartlett, Partner and Director of U.S. Operations for Full Circle Compliance, gave the export portion of the training, covering State Department regulations, Commerce Department’s Export Administration Regulations, and sanctions imposed by the Office of Foreign Assets Control. F.A.I.R. and NSSF report positive feedback for this type of basic training and may expand it at future conferences.

Day 2: ITAR Registration, Brokering, Voluntary Disclosures, and Compliance Programs

Day two of the conference was devoted to the controls over exports of defense articles governed by the Department of State, Directorate of Defense Trade Controls (DDTC). Danielle Pressler from DDTC Compliance gave an overview of registration requirements of the International Traffic in Arms Regulations (ITAR), recent amendments to the brokering requirements of ITAR, and the elements of an effective compliance program. She also discussed voluntary disclosures of violations to DDTC and encouraged self-audits to identify such violations. Pressler emphasized the fact that 99% of all voluntary disclosures are closed without further action.

Pressler’s remarks meshed well with a presentation from a panel titled “Designing and Maintaining an Effective Compliance Program.” James Bartlett from the Law Office of James E. Bartlett III, LLP, Johanna Reeves, Managing Partner of Reeves and Dola, and Thomas Trotto, from Immigration and Customs Enforcement HSI, made up the panel. Many of the compliance program elements emphasized by Bartlett and Reeves were similar to those in Pressler’s presentation. Attendees had questions for the panel about potential violations and when they warrant disclosure to State.

The final presentation at the conference was by Julio Santiago, a licensing officer with DDTC licensing. Santiago made remarks on licensing, end-user monitoring, permanent exports, temporary imports, temporary exports, congressional notification, and licensing exemptions.

The above synopsis was prepared by the F.A.I.R. Trade Group.

Additional Points Noted at the Importer’s Conference

ATF announced that three of its publications are undergoing revision in contemplation of the release of updated editions. The National Firearms Act Handbook and the Imports Guidebook are being revised and industry may bring needed revisions to the attention of ATF at the following e-mail addresses: nfahandbook@atf.gov and importsguidebook@atf.gov, respectively. ATF projects that new revisions of these publications will be available in time for the January 2015 SHOT Show.

ATF provided an update on their e-Forms. ATF has not yet even awarded the contract to the firm that will re-design that part of the system. Once a contract is awarded, the contractor’s personnel will need to go through background checks before they can begin work on the project. So, it could be mid-October before the contractor even learns the details of the issues to be addressed. The e-forms revisions are not expected to take place until sometime in 2015.

NFA Branch

William Boyle, III is now the NFA Branch Chief. Kimberly Ramsburg is now NFA Section Chief.

By October 2014, ATF expects to have 24 examiners in the NFA Branch to help clear up the backlog. By December 2014, they hope to have total of 29 examiners.

Alphonso Hughes, Division Chief, Firearms and Explosives Services Division (FESD) said that he is taking aggressive steps and “hopes” to have Form 1 and Form 4 processing time down to 6 months and Form 3 processing time down to 30 days by the end of the year. He recognized that this is optimistic but it is his goal to achieve.

Average monthly NFA Branch revenue is $1.5 million. The highest revenue month was December 2013 with $2.5 million received in revenue (thanks to the ATF-41P issue).

The NFA Branch is receiving on average 8,838 calls per month. In FY 2013, there were 44 Congressional Inquiries.

Presently, it is the first time since 2009 that the NFA Branch is processing more applications per month, than are received. The backlog is approximately 56,000 Forms, which is down from 81,000 in February.

Import Branch

It was announced that under Category 1 of the U.S. Munitions List, scopes no longer require a Form 6 to import.

Category 7 of the U.S. Munitions List has been modified somewhat substantially.

Under Category 14 of the U.S. Munitions List, gas masks no longer require a Form 6 to import.

Shotgun barrels must be brought in on a Form 6, even though they are not on the U.S. Munitions List, because the GCA says they must have a sporting purpose. It is to be treated as an implement of war and the model must be listed on the Form 6. Barrels are NOT being considered a firearm part.

eForms Updates

eForm 1s are back online. eForm 2s should be back online soon, by the end of the year or early next year.

eForm 3 and 4s will be next to go live, on the new site that ATF is developing, which may not be until sometime in 2015.

ATF still cannot update the website to reflect the one additional (not listed) requirement for the eForms password. eForms passwords must have 5 alpha characters.

Marking Variances and Electronic Recordkeeping

There is presently a 90 day turn around on Marking Variance Requests.

ATF says it is updating the Federal Firearms Regulations Reference Guide with new rulings and Q&A. The book hasn’t been updated since 2005.

In response to a question, ATF confirmed that it is a VIOLATION to use cloud storage for electronic A&D Records.

ATF-41P

ATF Counsel Andrew Lang stated that ATF is currently on track to make a decision by January 2015; however, he acknowledged that many of the comments filed by attorneys raised some issues that ATF hadn’t considered.

He stated that the rulemaking may get significantly sidetracked internally, depending on internal responses to their review of the comments and proposals on how to address the concerns.

In response to a question on why ATF didn’t provide the underlying materials used for drafting the proposed rule, Attorney Lang, in addition to saying the petition was posted by the NFATCA at some point in time on its website, said ATF hasn’t had requests for such material in the past (indicating in the words of one attorney present, that ATF may be in violation of the Administrative Procedures Act).

ATF Suspends Imports from 9 Russian Entities

On August 13, 2014, ATF announced immediate action to suspend import permits authorizing the importation of firearms, ammunition, and other defense articles involving Kalashnikov Concern and eight additional defense-related entities.

ATF initiated this action pursuant to guidance from the Department of State under the Arms Export Control Act, 22 U.S.C. 2778 (AECA), which directed ATF to implement the sanctions previously imposed by the Treasury Department’s Office of Foreign Assets Control (OFAC).

Background

On July 16, 2014, the Treasury Department’s Office of Foreign Assets Control (OFAC) designated Kalashnikov Concern as a Specially Designated National (SDN) as part of the Obama Administration’s sanctions on persons and entities in Russia determined to be contributing to the situation in Ukraine. They also identified seven other entities involved in the arms or defense industries in Russia.

It is important to note, however, that ATF’s actions prohibiting imports of defense articles from the targeted entities is under its authority of the AECA and is therefore broader than the OFAC economic sanctions. As mentioned earlier, the State Department has directed ATF to implement the economic sanctions pursuant to its authority under the AECA. The AECA authorizes the President, in supposed furtherance of world peace and the security and foreign policy of the United States, to control the import of defense articles. Consequently, the Administration’s authority under the AECA extends beyond economic sanctions and gives ATF the authority to prohibit the importation of defense articles involving any of the sanctioned entities, regardless of whether the targeted entities retain a financial interest in the defense articles. If the defense articles are manufactured by or otherwise involve one of these entities, they are prohibited from importation into the United States.

Russian Arms Industry Replacing Ukrainian Suppliers

The Russian arms industry has developed a plan to replace its Ukrainian suppliers, lost during the crisis in Ukraine, with companies in Belarus and Kazakhstan, an influential Russian daily reports.

Before the crisis, about 400 Russian defense contractors used materials and components produced in Ukraine, and 70% of all companies supplying the Ukrainian defense industry are located in Russia.

As the new Kiev regime started severing economic contact with Moscow, President Vladimir Putin urged Russian officials to ensure defense orders are fulfilled, and to start replacing Ukrainian suppliers with domestic production or imports.

FDIC Says It Will No Longer Target Firearms Retailers

Gun retailers are no longer on a hit list deemed “high risk” by the Federal Deposit Insurance Corp. after the banking regulator formally withdrew the list it put together that outlined what merchants may be considered risky for banks to do business with as part of the Obama administration’s “Operation Choke Point.”

The agency said its explanatory warning list “led to misunderstandings” about how it’s supervising banks’ ties to third-party payment providers, according to Bloomberg News. The regulator said it never meant to prevent banks from doing financial transactions with the types of businesses on the list.

Those that are operating with the appropriate systems and controls will not be criticized for providing payment-processing services to businesses operating in compliance with applicable law,” the FDIC said in its updated industry guidelines.

Richard Osterman, the agency’s acting general counsel, admitted to the American Banker newspaper that the list had been “misinterpreted” by financial institutions.

Republican lawmakers have criticized the FDIC for unfairly targeting legitimate businesses that operated in its so-called ‘high-risk’ category, including gun retailers and payday lenders. The Washington Times reported in May that many banks were dropping businesses in these high-risk industries as the bankers wanted to avoid higher scrutiny from the federal regulator.

The FDIC has been helping the Department of Justice run “Operation Choke Point,” which is intended to combat online fraud by cutting off fraudsters’ access to payment systems. House Committee on Oversight and Government Reform Chairman Darrell Issa, California Republican, has said the effect of the program has been to squeeze out legitimate businesses.

“If you empower the government to pick winners and losers within lawful enterprises, then there’s no place to stop,” Mr. Issa said in an appearance at the libertarian Cato Institute.

Industry advocates pushing to repeal Operation Choke Point said the FDIC did not go far enough. “Altering a website is window dressing and doesn’t end the unjust practices associated with Operation Choke Point,” said Brian Wise, a senior adviser for the U.S. Consumer Coalition, which is seeking an end to Operation Choke Point.

“While we support the FDIC’s decision to remove the list of ‘high-risk merchants’ from the FDIC website, damage has already been done to countless businesses across the country who have already lost their bank accounts,” he added. “Whether the list is published on the FDIC’s website or not, we expect banks will still be fearful of doing business with these lawful industries.” The author publishes two of the small arms industry’s most widely read trade newsletters. The International Firearms Trade covers the world firearms scene, and The New Firearms Business covers the domestic market. He may be reached at: FirearmsB@aol.com.

By Andrew Thomas

Our fighting soldiers – the recon units and scouts and expeditionary fighting forces that carry all of their equipment on their backs in and out of operations have learned this lesson well: ounces equal pounds. Soldiers have made an art of dropping unnecessary weight while in theater. They unpack their MREs just to ditch the large outer plastic bag. They forego conveniences and luxuries like an extra pair of briefs. They discard expensive equipment in the field; radios, gas masks and med kits; equipment they may need. Some cut their toothbrush in half – if they carry one at all. Sometimes they choose to carry less than they should of essentials like food, water, and ammunition. These combined efforts can result in dozens of pounds less to hump in a pack. Government contracted arms manufacturers have spent millions in research and development in attempts to lighten the load of our soldiers. The LSAT weapon project is a good example by cutting the weight the M249 SAW gunner had to carry nearly in half. It is based loosely on the M249 envelope, and uses caseless ammunition. Long before that, in the mid-1960s, Colt made the Model 608 Survival Rifle, based on the M16. They managed to whittle off unnecessary weight to bring it from 6 down to 4.8 pounds. It was intended to be carried in aircraft, in case of a crash, so flight crews could fight their way back to friendly lines. Before that, the M1 .30 carbine was the answer to the Garand’s size and weight; it was 25% shorter and 40% lighter than the Garand. It was ideal for personnel that were engaged in tasks other than direct combat. Mortar, tank, artillery, transport and support personnel found its size and weight preferable, and its capability sufficient. “Lightweight” is not a matter of convenience; it’s becoming quite necessary. This is the kind of thinking that spawned what is currently the world’s lightest AR-15 rifle, which weighs under four pounds.

It’s called the OIP (ounces is pounds) and it is indeed the lightest AR-15 carbine manufactured today. It is a full size carbine – not an SBR (short barrel rifle) and not a pistol. It’s built up to a standard; not stripped down to a compromise. The grip is the only plastic on the gun. The receivers and buttstock and buffer assembly are made of 7075 T6 tempered aluminum that is type III hard anodized on all surfaces. The upper features a dri-lube film inside. The muzzle brake and gas block and pins and screws and bolt carrier are bare heat treated titanium. The forearm is filament-wound carbon fiber. The barrel is nitrocarburized ordnance steel. There is no next generation rare earth element found on this gun. It’s not the product of quantum chemistry or other witchery. It’s the result of a “basic” AR-15 being stripped of the inferior and upgraded with the superior. It’s what happened when some mad gunsmiths got together and decided to affect a shift in the way we think about firearms.

The “blue sky” thinkers we refer to are the men of Bentwood Gunsmithing, in Henderson, Nevada. Bentwood is for the most part a general repair shop. They indeed offer service and repair on guns to walk-in customers. They can also authoritatively build, create, modify, and improve weapons of all platforms; for all purposes. They sponsor a few of the world’s top action shooters; the guns wielded by those champions are made at Bentwood. They build and maintain duty and service weapons for many departments and agencies; foreign and domestic. It’s not enough to say that Bentwood’s staff is factory trained: it is actual fact that security, police, and military agencies and firearm manufacturers send their technicians to receive armory training from the man in charge at Bentwood Gunsmithing, Matthew J. Babb. Through experience, interaction, and feedback from such a broad industry sample, Bentwood’s Gunsmiths have learned what is required of a gun; and where the gun falls short of fulfilling its role.

The first prototypes of the OIP project began in 2009 at the request of an Army Ranger that returned home from Afghanistan. This Ranger had carried a MK48 machine gun for several years in theater. It was heavy and unwieldy. The Ranger offered up the idea to Dave Lake, one of Bentwood’s Gunsmiths, to build a rifle that was “just a rifle.” Those were his words. He wanted a rifle that consisted only of what’s necessary to fire bullets safely, reliably, and accurately. The Ranger wanted a rifle that he could carry while biking or jogging in the woods. This idea of ultimate simplicity in a rifle became Dave’s mission. The early versions were built on vintage Colt AR-15 receivers – the old uppers without forward assist and shell deflector, and lowers without pivot pin plungers and fences. These receivers were fitted to pencil thin, shortened barrels. Thin wall tubing was welded on the muzzle to make legal length. Later versions of the lightweight project involved skeletonizing the receivers. Instead of using commercially available buffer and stock assemblies, the buffer from a carbine was used, as it weighs less than that of a rifle; while the tube from a rifle was used, as it weighs less than that of a carbine. A hollow plastic spacer below the buffer assembly is all that was needed to make this combination work. The barrel was aggressively fluted – more flute than barrel and a lightweight carrier installed. The takedown pins and selector barrel were hollowed out. The gas block was condensed to one fourth the bulk of the lightest commercial option. Even the hammer and trigger were ground down to a third their original thickness while preserving proper function. Sometimes each new effort would show a loss of an ounce or two; though sometimes progress came only in fractions of an ounce.

In the summer of 2013, Bentwood Gunsmithing partnered with Battle Arms Development to create an ultra-lightweight receiver set dedicated to this project. The result bore the compelling strut-and-web design seen here. Careful engineering created a receiver set slightly stronger than a basic forged receiver set, and 30% lighter. The barrel was optimized by incorporating a unique machine dimpled surface. This patented feature is used under license granted by Knight’s Armament Corporation. The dimpling process retains most of the barrel’s rigidity while cutting the barrel’s weight from the typical 28 ounces to a scant 18 ounces. During its development, as the rifle dropped below the 5 pound mark, there were resultant negative side effects. Recoil was uncomfortable and handling during fire became strained. The OIP’s control and firing characteristics would need to be improved, while maintaining a net weight loss.

The OIP, in its final revision, weighs just under 4 pounds dry. More effort is required to pull the trigger on a Glock pistol than lift this rifle. This lack of inertial mass makes a brusque recoil impulse and there were corrective measures applied to the gun to keep it under control. First, and most obvious, is the muzzle brake. It’s machined from titanium bar stock. Its weight is half that of a steel brake. The porting and internal geometry are not random. The design is the product of thorough testing, study, and experimentation. There is no equation that can be applied to calculate the dynamics of a muzzle brake; and no broad definition to quantify the effect. Caliber, chamber, bullet weight, barrel length, gun weight, gun geometry, shooter weight and stance and method of holding the gun all skew the result. Empirical data was gathered from many prototype brakes as over 1,000 rounds of M855 ball were fired in front of a slow motion camera from a “recoil machine,” a fixture built by Bentwood specifically for this project. During their work, Bentwood discovered that a muzzle brake works by two principles. They are described as the flow and foul of a gas (exiting the muzzle). More of the “flow” effect built into a brake’s baffles and chambers results in a slower; albeit still present, recoil impulse. This style returns less overall effective recoil attenuation for small calibers. It works well with heavier weapons, and larger cartridges. The property of flow can be exploited as directional control, to counteract muzzle rise for instance. The “foul” effect can create highly effective recoil control; sometimes too much. In the case of this 4-pound rifle, one overly effective brake originally used for testing actually yanked the rifle forward – away from the shooter – making follow up shots next to impossible. A “fouling” brake also makes for an overwhelming blast impulse back to the shooter. The result of these efforts is a brake that is balanced in its effect to work optimally with this rifle.

More recoil mitigating features are found on the other end of the gun. The proportion of the stock assembly is the result of some trial and error and some consultation with some experienced professional shooters. It is an accepted fact that there is a proper way to “saddle” a rifle. By doing so, the shooter effectively gains more control over that rifle. This method asks that the shooter mount the rifle low in the shoulder, while keeping the body square to the direction of fire. The head should remain upright and rest forward and atop the stock. The length and drop of the OIP’s stock were devised to encourage correct shooting form; and as part of its design, is meant to cause discomfort if the rifle is held incorrectly. The pistol grip also plays its part. As it is nearly vertical, it encourages the arm to swing farther forward, resulting in a better “pocket” in the shoulder for the stock to lock into. It also lets the hand and wrist relax more than a rearward swept grip; facilitating better trigger control. Other secrets lie inside the OIP’s buffer tube. The buffer’s design has been enhanced from the standard configuration. The details of these structures will not be illustrated here; suffice to say that cyclic function and recoil impulse are optimized while achieving an overall weight savings. The recoil spring system, called the “Flatline” is available as an accessory to be used in any AR-15. It is perhaps the smartest part on this rifle. It replaces a conventional buffer spring with 3 new components; 2 springs and a little plastic ring. It’s so simple but so effective. The motion of the recoiling mass of the bolt group and buffer is attenuated by multiple springs that slow and reverse motion at multiple rates. The result is a rifle that operates near the constant recoil principle, with enhanced reliability, and with almost no recoil energy passed on to the shooter.

The OIP is offered for sale only as kit, though some of the developments will be for sale as accessory items later this year. The kit includes an optic, optic mount, sling, magazines and a discreet carrying case. The optic is the Aimpoint H1. It is not the lightest red-dot on the market; it was chosen for being the best red-dot that is light. Weight savings was a goal in the OIP project, but it never came at a compromise to the rifle’s function. The magazines included are made by Lancer Systems. They are indeed lighter than any metal magazines and come at a weight savings while maintaining reliability. Lancer Systems magazines are transparent polymer, and feature a metal top section that includes the feed lips and notch for the latch. Here again, weight was dropped without sacrificing function. The case was chosen for its utility as a multipurpose pack. It does not look like a gun case. It can be carried in the hand or slung over shoulder or across the back. It’s meant to blend in among gym bags and backpacks we might see attached to joggers, bikers, and commuters these days. It features padded exterior walls, many compartments and a place for a hydration bladder. The rifle is stowed in a broken-down state in the main compartment. The sling is an elastic single point style without padding; it’s simply not required. This rifle could be carried comfortably on a single strand of para-cord.

The small bits on the OIP are all very special as well. The titanium gas block is almost not there – it weighs less than the gas tube. The forearm is glued to the barrel nut as screws would be too heavy. The takedown and pivot pins are titanium and available from Battle Arms Development as the TiEPS. The screws that hold the grip and buttplate are also titanium. The selector lever is another Battle Arms part; their short throw modular unit; though the OIP variant is made of skeletonized aluminum. JP Rifles supplies the OIP with its trigger mechanism. It offers a 4 pound pull with adjustable sear engagement, pre travel and over-travel. It’s also the thinnest trigger on the market, thus it is the lightest trigger on the market. The bolt carrier is machined from solid titanium. The bolt and gas key are nickel boron coated, magnetic particle inspected, Carpenter 158 steel. The entire assembly is of premium quality and workmanship. This bolt carrier group weighs 4 ounces less than a regular steel bolt group.

The OIP is somewhat limited in its mission adaptability. It cannot accept forward Picatinny rail sections. It is not compatible with M-lok or Keymod accessories. The only upgrade is an optional flashlight mount that connects to the Fortis Scope base. By locating the light just ahead of the receiver and atop the forearm, the rifle’s balance remains manageable, and gives the user’s thumb direct access to the light controls. Through its evolution, the OIP has become a narrowly focused weapon. It’s built for long term carry, rapid deployment, and the aggressive use against armed threats. It really belongs to those who need to carry a weapon all the time – security guards, standing a post or traveling with a VIP, police officers on bicycles, and even the Secret Service. Any of the alphabet agencies could use it to good effect. Law enforcement and anti-terrorism groups are encountering an ever- growing domestic threat. The convenience and concealability of the handgun is becoming overshadowed by its limited range and power. Those that serve in our defense need real firepower at their side. There is a demand for, and a growing supply of small, potent weapons that punch above their weight and bridge the gap between pistols and assault rifles; known generally as PDWs. The poster child of this type of weapon is the Heckler and Koch MP7. It ignores the line between the sidearm and the assault rifle, is lethal up to 200 meters and boasts armor-piercing capabilities. It carries a 30-round magazine of hi-velocity .18 caliber projectiles, and can fire them in full auto at 950 rpm with no appreciable recoil. The operator does require extensive training and familiarization to put the MP-7 to good use. It is roughly twice the size and weight of the average service pistol; it weighs 4.2 pounds empty. Well then, we see now that there is a balance to be reached between size and weight and firepower and practicality. The OIP weighs 4.2 pounds with the aimpoint attached. The 5.56mm ammunition is well proven; and the AR-15 platform is well known. The AR-15 platform requires no new level of training, no new armory certification, and can use common parts and common ammunition. The 5.56 cartridge doubles the range and effect of the 4.6mm round used in the MP-7. In a world where insurgents often present with submachine guns and assault rifles, our counterinsurgent forces should, if at all possible, out-gun the bad guys. “Too much gun” is just a negative way of saying, “decisive application of force.” Comparatively then, the only drawback to the OIP is its size; a flaw easy to overlook when weighed against the advantages the OIP affords its user.

Our evaluation at the range did not disappoint. We were quickly mobbed by other shooters and range staff; all very curious about the rifle. They were all caught completely off-guard when we passed the rifle around for close-inspection. The “gallery” we had attracted became abuzz in comment about the OIP’s feather-lite feel and perfect balance. For some, the looks of the gun caught them; it was love at first sight. There were members of this crowd that were skeptical, so we gave them all a chance to fire it. One way or another, by holding, firing, or merely looking at the OIP, everybody at the range that day became a believer. After we shot the gun, any dubious feelings we had about the OIP were put to rest as well. Bentwood’s claims of superior balance, ergonomics, firing and handling characteristics are all very true. If we didn’t know any better, we would swear that every bit of R&D went into making this thing perform. The exquisite form the rifle has taken could just be a fortunate side effect. And what’s satisfying is that it’s not made of techno-fluff and rainbows like some boutique AR-15s can be these days. The OIP is a real player. It meets or exceeds accuracy standards set forth for the M4 carbine. Our test rifle came fitted with an Aimpoint H1 red-dot. There is no place for a magnifier on the receiver, so our long range accuracy results would be achieved without magnification. Standing unsupported at ranges up to 300 yards, we could easily deliver all hits “in the black” on an NRA B27 silhouette target. At 100 yards from a rest, using M855 ball ammunition, our best groups averaged 3-inches on target. For close-in rapid fire results we used a shot timer set to a par time of 1 second per target placed downrange. Even on targets out to 50 yards, we were able to make our hits and transitions within our timed goals. This speaks to the rifle’s superb handling traits. Moving the OIP from target to target is really as easy as looking at the next target. The rifle instinctively follows and there’s so little effort required to move it with zero recovery time between shots. This kind of speed and handling is just what 3-gunners are seeking. The properties of all metal parts and surface coatings exceed our military’s operational standards for wear, abuse, and normal operation. After over 1,200 rounds at the range over two days, including all the shooting by the folks at the gun range, there were no jams, failures, or malfunctions of any kind. Our evaluation took two days because of the severe weather of the Nevada desert in fall. The first day saw high winds and dust, followed by torrential rain that combined with the dust to form mud. Perfect opportunity to tempt fate; the gun was not cleaned before day 2 yet we finished our range testing without a hitch. This does not suggest that the OIP is superior in this capacity as the limits of the AR-15’s ability to survive abuse have been long established on the battlefield. We don’t suggest that Las Vegas is as bad as Afghanistan or Panama, but it is one of the harshest places in North America, and that’s a good enough test for most of us. So the OIP is as good as any other good AR-15 at roughing it in the elements. If we must complain about something, we will complain about the very hot forearm. During fire, the black carbon fiber tube absorbed radiant heat from the barrel and the desert sun like a charcoal briquette. We urge the use of a glove for sustained fire, or use the “magwell” grip with the front hand. At our inquiry, we were told by Bentwood Gunsmithing to expect other versions and caliber options in the future. They declined to let slip any dates or details. We’ll cross our fingers for a 300 Blackout or even a pistol variant. It would be selfish to hope for an AR-10 to receive the OIP treatment.

The OIP is produced in very limited numbers, and each rifle is assembled by one man and inspected by the other at Bentwood Gunsmithing. The OIP is unique, exclusive, beautiful, and powerful. It’s a rare thing that is as intriguing to see and hold as it is to shoot. It’s like a greyhound; skin and bone and muscle that was built to run. This rifle begs to be taken to task. But like most of your guns, you don’t buy them out of necessity. You’ll buy the OIP to make your shooting buddies jealous. You want to be the object of envy at the shooting range. You don’t have to carry a badge and wear a suit and sunglasses and an ear bud and speak into your cuff to justify buying it; but if you are lucky enough to get an OIP, you’re welcome to don the sunglasses and ear bud.

By Chris A. Choat

S.W.A.T. Firearms Industries is a small firearms manufacturing shop based in the town of Campbell, Texas. The shop only has a handful of employees but is turning out some new custom rifles that are very impressive. The new rifles feature the company’s own billet upper and lower receivers as well as new products that the company is adding to their line. The newest rifles bear the designation of the MSR-15 (Modern Sporting Rifle).

This author was first introduced to the company’s quality products when they were contacted about using one of their billet lowers to be used with a, then new, complete billet upper. The new upper featured quick change barrels and the S.W.A.T. lower complimented the design perfectly. (See the article on Faxon Firearms ARAK in Small Arms Review Vol. 18, No. 1.) During the testing for that article, the quality and fit of their lower receiver and all the associated internal parts was quite impressive.

The company is now producing complete rifles and is offering their guns as custom built creations with the customer picking out the options that he or she wants on their rifle. S.W.A.T. Firearms builds the guns one at a time specifically tailored to their use or mission; whether it is a gun built for 3-gun competition or a gun built for tactical operations. The gun built for this article was done as a 3-gun competition rifle. S.W.A.T. Firearms can source most any parts for a custom rifle or the customer can supply their own accessories.

I chose to let S.W.A.T. Firearms build the rifle with some of their newest parts and options that they supply but I chose to put on a railed forearm of my choosing. The one I picked was the new Samson Manufacturing 15-inch Evolution Keymod rail forearm. This forearm is the latest addition to their railed forearm line. The Evolution Keymod features standard Keymod slots at the 3, 6 and 9 o’clock positions. In addition, the Evolution Keymod maintains the ability to accept standard Evo accessories at multiple angles around the rail through the original’s cut slots. This allows the user the advantage of a much larger variety of accessories while still having cross platform capability where it is needed most. The new Keymod forearm has the same hand feel as its older brother, but is even lighter. The inside diameter, 1.5 inches, is also the same as the first Evo allowing a sound suppressor to fit inside the forearm for short barrels. The 15-inch model was chosen to cover the new gun’s rifle length gas system. The Evolution rail forearms are totally free-floating, attaching only at the rear around the barrel nut by means of a thermal bushing. The units all come with a Mil-Spec Type III black hard-coat anodized finish.

The main features of the new rifle are, of course, the billet upper and lower receivers. They are both 100% machined, in house, at the S.W.A.T. Firearms shop. They are both milled solid blocks of 6061 T-6 aluminum and are done in a Mil-Spec Type III black hard-coat anodized finish. The receivers can also be ordered with a Cerakote finish in just about any color the customer wants. S.W.A.T. Firearms offers their off-the-shelf guns in colors such as Tastanium Devil, Desert Storm, Dragon Slayer Red and Prison Pink so the shooter has the option of mild or wild.

The upper features a full-length Picatinny rail across its top and can be ordered either with or without the forward assist. The test gun had no forward assist as most 3-guns don’t want that option. Installed in the upper was one of S.W.A.T. Firearms extended charging handles. This handle has an extended, oversize release lever for quick manipulation. The billet lowers all have an integrated cold weather trigger guard that is enlarged at the front to accommodate a gloved finger. The lowers are finished the same as the uppers. Another great feature of the lower is the 60 degree flared magwell at the bottom to help guide the magazine into place. If the shooter is slightly off when inserting the magazine this flare guides the magazine into position. This is an important feature for competitors or anyone in a stressful situation. The test guns’ upper and lower were a matched set and fit together perfectly. This is also helped by an upper receiver tensioning screw that is located in the lower receiver. This small polymer tipped screw can be adjusted from under the pistol grip to provide tension against the upper receiver so that even the tiniest amount of play can be eliminated. Pivoting the upper and lower receivers closed reminds one of shutting a safe door. The lower also came with KNS Precision anti rotation trigger and hammer pins. For those not familiar with these, they are pins that have milled notches on their ends and are locked in position with a mating crossbar. This keeps the hammer and trigger pins from rotating in their respective holes and wearing the holes out. This may not seem like a necessary accessory but is very important for guns that have thousands and thousands of rounds put through them like 3-gun firearms or select-fire guns.

Other features installed on the test gun’s lower included S.W.A.T. Firearms own extended take down pins and their National Match 2-stage trigger. The pins are extended and knurled on the ends to get a good grip on them for easy removal. The trigger on the test gun had a very crisp 2-stage break with a trigger pull of only 3.6 pounds. These are very nice triggers and once you have tried them you’ll want them on all of your guns. The lower was equipped with an Ergo Grip pistol grip. These grips are made of a rubber material that is extremely non-slip and also has very slight palm swells and fit the hand perfectly. At the back end the receiver had a black MagPul CTR collapsible buttstock. The CTR is a favorite as it is simple yet locked up positively with absolutely no wobble or rattle.

S.W.A.T. Firearms uses E.R. Shaw barrels and the test rifle was equipped with an 18 inch model that is a nice compromise between the 20 inch rifle barrel and the 16 inch carbine barrel. This barrel is their SPR (Special Purpose Rifle) model that has a 1 in 9 twist rate. It’s hard chromed as is the AR-15 style bolt that comes in the gun. The barrel is threaded 1/2 x 28 and was capped with one of S.W.A.T. Firearms own muzzle brakes called the MB-3. This brake produced a very mild muzzle blast and absolutely killed all the muzzle flash. The test gun had a rifle length gas system that produced very mild recoil along with positive functioning.

The gun was finished in Tungsten Gray Cerakote. This included the upper and lower receivers as well as the Samson Keymod forearm. The barrel, buffer tube, stock, pistol grip, charging handle, fire control parts, take down pins and magazine were left black that made for a very attractive gun drawing numerous comments at the range.

Testing was done with a number of types of ammunition that included several bullet styles and weights. With the 1 in 9 twist, naturally the gun liked the heavier bullets in the 68 to 75 grain range. In fact one group shot with the rifle put 3 shots into one ragged hole at 100 yards. The trigger probably had a lot to do with this. The group was shot with Hornady .223 75 Grain Boat Tail Hollow Point Match. The gun functioned perfectly with no failures of any kind. It fed and ejected without a hitch, which is expected in a rifle such as this. The gun was fired from the bench and used in 3-gun competition scenarios as well. It is fast handling, very accurate and reliable to a fault. If you are looking for a 3-gun rifle to compete with or a rifle that can be used as a tactical gun, take a look at the new custom MSR-15. It’s a perfect fit no matter what the purpose.

S.W.A.T. Firearms, Inc.
6585 East Interstate 30
Campbell, TX 75422
Phone: (903) 862-2408
www.swatfirearms.com

Battle Arms Development Ambi Safety/Selector (item BAD-CASS-FA). This kit features interchangeable levers in 6 sizes and shapes. Ambidextrous control means quick control.

By Todd Burgreen

Glock made noteworthy additions to their product lineup at the latest SHOT Show with the Glock 41 (G41) .45 ACP and Glock 42 (G42) .380 ACP. These two new Glock handguns are on opposite sides of the use spectrum. The G41 is a dual purpose “Tactical/Practical” full size weapon equally at home in duty/service roles or in competition formats. The G42 is an ideal concealed carry candidate. The focus of this article is on the Glock 41. After erupting on the scene in the early 1980s with the Glock 17 (G17), Glock pistols quickly evolved into a benchmark for personal defense, law enforcement, and military polymer handguns. Glock handguns are ultra reliable, accurate, tough, and simple to operate; all at a competitive market price. A review of the personal defense handgun market makes it clear that Glock is a design standard for these materials, that many others are still chasing. Many detractors would have you believe that Glock has grown complacent by not introducing any new designs that depart significantly from the template laid by G17’s arrival in 1982. In fact, Glock handguns are into their Fourth Generation (4th Gen) of refinement being introduced at the 2010 SHOT Show. The 9mm G17 and .40 S&W G22 were the first models introduced in the Fourth Generation with the other models steadily added.

A quick rundown of what sets each Glock Generation apart is in order to better appreciate Glock evolution. The 1st Generation, typified by the G17 introduced in the early 1980s, was created to satisfy the Austrian Ministry of Defense request for a new service pistol replacing the P38. The grip was smooth with little texturing and no accommodation made for lights or other accessories to attach to the frame. 2nd Generation Glocks had serrations added to the front and back strap of the frame. A steel plate stamped with serial number was embedded into 2nd Generation frames at the dust cover to satisfy U.S. BATF regulations. Research indicates that 1st and 2nd Generation Glocks were built with two pin frames with all subsequent models using a three pin frame. Third Generation Glocks were introduced in the late 1990s. Highlights of the Third Generation consisted of an accessory rail (Universal Glock rail) being standard for the use of lights, lasers and other accessories. Thumb rests were added on both sides of the frame and finger grooves were added to the front strap. “Late” Third Generation Glocks had the extractor modified to serve as a loaded chamber indicator. As mentioned above, Third Generation Glocks had an additional cross pin added. The pin is labeled as the locking block pin and is located above the trigger pin. The locking block is enlarged in the Third Generation Glocks. The larger locking block and additional pin was added for increased durability and distributes force across a larger area.

The 4th Generation Glock reflects a combination of both ergonomic and internal changes. Many will point to Glock finally acceding to market demand by offering interchangeable backstraps of different sizes with the 4th Generation introduction. It is suspected the increasing amount of competitors offering the ability to change grip sizes was making too many inroads into both the law enforcement and civilian markets. Grip sizes are small, medium, and large frame. Grips are changed via removing a single pin. The G41 Gen 4 Glock comes with a smaller integral grip compared to the Gen 3 Glocks with the medium and large grips fitting over the frame as a user sees fit. Basic grip size is smaller with the 4th Generation introductions due to Glock lessening the backstrap “hump.” This aids shooters with smaller hands by reducing the circumference of the grip frame. Adding the medium grip size of the 4th Generation Glock can be likened to the grip found standard on 3rd Generation Glocks. The magazine catch on the 4th Gen Glock is enlarged and reversible requiring no additional parts to do so. 4th Generation Glocks come with three magazines configured with the cutout catches on either side of the magazine body. All previous Glock magazines will work with the 4th Generation Glock as long as the magazine catch is configured on the frame’s left side.

Internal changes associated with the Gen 4 Glock centers around the dual recoil spring similar to what is currently found in the “mini” Glock 26/27. Glock literature points to the dual recoil spring assembly reducing recoil impulse and increases the life cycle of the pistol by limiting wear due to the firing cycle. Non-Glock sources point to the dual spring as a necessary change to address reports of reliability issues with G22s when shooting certain types of ammunition with a light mounted to the weapon. The dual spring changes slide rate and thus reliability. The spring is a dual compression type with the captured springs operating at different rates. Though no formally tested recoil dampening rate reports have been published, subjective estimates from 10%-30% have been bantered about, especially with the “snappier” .40 S&W and .357 SIG chambered Glocks. The G41 tested herein in a 4th Generation type. The dual recoil spring is expected to have a longer service life compared single spring design found in earlier generation Glocks.

Glock eliminated the possibility of switching springs and slides between 4th Generation models and its predecessors by giving the dual recoil springs a thicker guide rod and end plug so it will not fit in any non-4th Generation slide. The Gen 4 slide has been altered to not accept previous guide springs and furthermore prevents slide interchangeability between Gen 4 and earlier Generation models. Gen 4 slides are stamped accordingly to aid in preventing confusion. Another internal change is in the trigger bar layout and is supposed to increase life expectancy. The trigger housing is slightly different due to the grip frame and mirrors Gen 3 SF models.

Manufacturer and price range serve as no guarantee that a handgun is able to perform immediately after purchase. Yes, many deficiencies are quickly remedied by “breaking in” a pistol by use or making slight adjustments to various parts. This does not have to be acceptable. A Glock is one of the few handguns you can count on being ready to go straight out of the box. Glock’s solid performance over the years is sometimes neglected or taken for granted, particularly by firearms publications. This stems from the constant focus on the newest product introductions. The G41 allows for renewed focus on what Glock offers in terms of performance.

The G41 joins other specialized Tactical/Practical “long slide” Glocks such as the G34 (9mm) and G35 (.40 S&W). The Glock Tactical/Practical family tree extends back to the hard to find G17L (9mm) and G24 (.40 S&W). The Glock 34 and 35 were born from the need to shorten the slide of the G17L/24. The G34/35 slide was shortened to fit size constraint rules imposed by certain competitive shooting sanctioning bodies. In general, the dimensions follow the classic 1911 pistol’s outline. With the G34/G35 introduction, G17L and G24 production was throttled back. Glock’s reasoning, as efficient as their handguns were, was that there was no need to continue importing the Glock 17Ls and G24s in the same quantity with the Glock 34/35’s introduction.

Let’s review what sets the Glock 41 apart from other Glock handguns outside of the Tactical/Practical category. This is an instance where size does matter. The G41’s 5.3 inch barrel is the most obvious departure giving the G41 an overall length of 8.9 inches and a sight radius of nearly 7.6 inches. For comparison’s sake, a full size 1911 has a sight radius of 6.8 inches. The G41’s longer sight radius is more conducive to accurate shot placement at distance. With the G41 a proficient shooter will find it possible to accurately engage targets at 50 yards and cover had better be sought by any intended targets out to 100 yards. Proven Glock ergonomics combined with the slide’s long track during recoil and manageable .45 ACP muzzle signature allows for a very stable sight picture no matter how many or how rapid rounds are fired.

It is not hard to fathom why select elite special operation units choose the Tactical/Practical “long slide” G34/35 Glocks with the G41 sure to follow the same path. The G41 equipped with a Glock GTL 21 tactical laser/light on its rail is a lethal CQB weapon in trained hands. Another worthy addition would be a Kriss Extended G21 magazine offering 25-round capacity for the G41. This same configuration, GTL 21 and Kriss Extended G21 magazine, would find beneficial use in the civilian world as a “nightstand” defensive handgun.

A loaded G41 magazine with one in the chamber adds up to fourteen rounds of potent .45 ACP firepower in a package similar in size to the classic 1911. The G41 represents the quintessential balance of size, weight, capacity, and cartridge potency. As mentioned earlier, the G41’s frame is a Gen 4 type, meaning it is not as large as the previous Gen 3 G20 (10mm) / G21 (.45 ACP) frame that proved such a handful – no pun intended – for anyone without extra-large hands. The prior 4th Gen reference is important due to the G41 benefiting greatly from the associated design tweaks. The G41 comes with four (4) interchangeable backstraps allowing a user to adjust to the feel they want. Two grips featuring extended beavertails are also included with the G41. Another nuance discovered with the Gen 4 G41 was that its slimmer slide resembles a G17 compared to a G20/21 allowing for its use in a wider range of holsters. This is significant with G17 holsters more easily available than G20/21 holsters. The G41’s slimmer slide contributes to it weighing less than a G21. The G41 weighs 27 ounces empty; this is a couple ounces less than the G21 despite its shorter slide.

The G41 .45 ACP was test fired using Federal, Winchester, Black Hills, Hornady and Wolf ammunition. Loads fired ranged from 185 grain to 230 grain JHP and FMJ bullets. Brass and steel cases were also tested in the G41. Approximately 450 rounds were fired while compiling this article. No malfunctions were experienced. After the G41 sights were verified at 25 yards, T&E testing consisted of monotonous hammering of steel plate racks and popper targets at 7, 15, and 25 yards. Man sized steel targets were sporadically engaged at 50 and 100 yards as well. All of the premium loads tested from Federal, Winchester, Black Hills Ammunition, and Hornady generated 3-inch groups at 25 yards. From a more practical perspective in terms of handgun performance, the G41 produced a 100% rating over a 60-round law enforcement proficiency test frequently used to gauge different handguns. The test is timed fire from the holster at various ranges stretching from 5 yards back to 30 yards. Unscientific assessment would be that the “snap” of the slide in its rearward travel is indeed reduced with the G41 compared to a 3rd Gen G21 .45 ACP that was handled alongside it even though the G41 is lighter than the 3rd Gen G21 by a few ounces. This has to be attributed to the dual recoil spring found in the G41.

T&E was conducted at Echo Valley Training Center, a private range located near Winchester, VA, where many local and federal law enforcement tactical team members train. It is difficult to convey how many shooters at the range perked up when they noticed the Glock 41. Every time one of them got to handle and shoot the Glock 41, a convert was obtained. Their duty weapons span the gamut, including custom tuned 1911 pistols, but all appreciate what the G41 offers in terms of accuracy, reliability, handling, capacity, and lethality.

Considering that the G41’s design intent as a Tactical/Practical offering it was decided to dedicate some time evaluating the G41 using several drills experienced during training at Suarez International, TMACS, Tactical Response, Storm Mountain, and other schools. Drills included working around breaching facades, door entries, and other CQB activities typified by experiences encountered in shoot house environments. A premium is placed on a quick handling accurate handgun such as the G41 with multiple rounds fired in quick succession the norm to put a target down. The natural point-ability of the G41 comes into its own in this realm. The full size grip frame and overall balance of the G41 made felt recoil negligible. A BlackHawk Serpa holster on a High Speed Gear patrol belt served as primary means of carry for evaluation purposes.

The Glock “secret” to success is minimal operating controls, relentless reliability, and consistent manageable trigger pull. While the grip size is different between the newly introduced Glock 41 and Glock 42, the position of the slide and magazine releases will instantly be familiar. Simplicity should not be confused as lack of refinement. As experience and knowledge has expanded, Glock reliability and solid performance has become more entrenched as a standard that many other polymer handgun manufacturers are competing against.

Sites of Interest

Glock
6000 Highlands Pkwy
Smyrna, GA 30082
(770) 432-1202
www.glock.com

Black Hills Ammunition
PO Box 3090
Rapid City, SD 57709
(605) 348-5150
www.black-hills.com

Echo Valley Training Center
www.echovalleytrainingcenter.com

Hornady Mfg., Inc.
3625 Old Potash Hwy
Grand Island, NE 68802
(800) 338-3220
www.hornady.com

Stonewall Arms
2438 Valley Ave
Winchester, VA 22601
(540) 535-2190
www.stonewallarms.com

Winchester Ammunition
427 N. Shamrock St
East Alton, IL 62024
www.winchester.com

KRISS USA
PO Box 8928
Virginia Beach, VA 23450
(855) 574 7787
www.kriss-usa.com

Here one can observe the BlackHawk! SERPA thigh holster that Marines are currently being issued, and can compare that to the British Radar thigh holster setup for a Glock 17.

By Miles Vining

“The second you stop learning, is the second you start dying” is a phrase that the author used when talking to Afghan National Army soldiers while teaching a counter IED (Improvised Explosive Devices) class in Helmand Province, Afghanistan. The point to be made was that in an IED environment, a soldier’s most important asset is his mind and how he solves or predicts certain situations. This maxim can be applied to anything involving life or death with military, law enforcement or civilian applications.

Soon after, the author took advantage of an opportunity to fire some of the small arms belonging to our allies across the pond while being forward deployed to Camp Leatherneck (British Bastion, Afghan Shrobak are joint bases).

The author took this opportunity as a means to examine the differences between the British Army’s and U.S Marine’s small arms approaches. How the two countries view safety, range operations, shooting qualifications, and immediate action procedures. Although Marines are known for their ability to “improvise, adapt, and overcome,” much of the service is very regulation bound, and outside the box thinking is often met with severe criticism and disdain by higher echelon leadership. This would seem surprising considering Marines are at the forefront of Combined Arms warfare, amphibious operations, and low intensity conflict. The ever-changing theory and innovative strategy is present, but within individual units, officers and senior enlisted possess an attitude of, “This is the Marine Corps way, and nothing else works as well.” Some of that is certainly “esprit de corps” but a lot of it is narrow mindedness and unwillingness to accept that there is always room to improve. This is quite troubling because if any organization is to succeed, it has to be fluid with the changes occurring in its environment and maintain an open mind about what works and what doesn’t. As an example, infantry Marines know their internal weapon systems to the point of muscle memory. But knowledge of their allies or enemy’s weapon systems is immensely limited. There are Foreign Weapons Instructor courses offered in Quantico but these are small in number and are mostly attended by Marines in an instructing position, and not the typical sergeants and corporals leading squads into combat. The underlying message in this essay is to keep an open mind and not let rigid standards prevent becoming more knowledgeable about what is out there, both bad and good.

Adopted as the national service rifle in 1987, and replacing the L1A1 FN FAL, the SA80 (Small Arms of the 1980s) got off to a rocky start in terms of reliability. British troops in the first Gulf War were taping their handguards up to prevent jams from the ever present sand. Some of these issues were due to the fact that the SA80 had been intended for use in a land war in Europe, and not in the Middle East. The problems continued until the late 1990s, when the SA80 and Heckler & Koch metaphorically saved each other. Heckler & Koch was going through a financial crisis and the SA80 seemed to have no reliable version in sight. Heckler & Koch took up a modification contract, which culminated in the L85A2 and L85A3 versions of today (same rifle but re-designated L85). These are currently in use with all of the British Forces and have several variant offshoots in shorter carbines, single fire cadet rifles, and the LSW (Light Support Weapon).

One fact that is often omitted about the rifle is that it gave the United Kingdom (an army to be reckoned with), a service rifle with magnified optical sights. Of course Austria had the Steyer AUG with its optical sight in 1978 but the Austrian army doesn’t deploy internationally as much as the UK does. To put this in perspective, the U.S. Marine Corps didn’t begin fielding optical sights until Operation Iraqi Freedom in 2003 and even that was as a single designated marksman in every rifle squad. The rest of the infantry had to wait as late as 2005 (seventeen years after the SA80) to have the 4x Trijicon ACOG (Advanced Combat Optical Gunsight), RCO (Rifle Combat Optic). The U.S Army was on a similar schedule. Today, almost every modern army has optical sights on their service rifles, even some third world armies as well.

The course of fire and the range were very simple; some basic combat marksmanship drills, shooting from the prone, kneeling, and standing, on the move and from different yard lines within the 36 yard range. The author fired two full magazines through the L85A2 and a magazine through the Glock – nothing too strenuous or torture testing due to the range and time constraints. The conduct of the range was professionally administered and very well disciplined. This was done in a subtle manner unlike many Marine ranges where conduct is strictly controlled. Even though commands were simple, safety was very much paramount and at no time was an unsafe act allowed to continue.

The L85A2 fired was by all means a modern rifle compared to the original SA80, apart from the original SUSAT (Sight Unit Small Arms, Trilux) sight. Most of the British infantry that go outside the wire are equipped with the Trijicon ACOG or an Elcan sight but the rear echelon soldiers have the old SUSAT. Apart from that, the rifle has a full spectrum Picatinny rail system as the handguard, grip pod, and Magpul Emags are issued out en masse. The sling is a thin webbed green type that is used mostly in a garrison environment. On patrol, plastic clips are issued and the rifle can be clipped to an Osprey (British flak jacket) – in other words making it a One Point sling. The rifles on Bastion have a black finish but this is painted over with a light tan that stays on though rifles in theater for a good period of time are seen with this starting to wear off.

Being a bullpup, the rifle itself is very compact with a full length barrel, and its width is noticeably thin, compared to an M16/M4. This translated into being able to get a very tight stance. It is very appreciable for offhand shooting and urban operations. The tighter a shooter can be with his rifle, the more control he can exert over its effects at a close range. This was especially evident at the 36 yard line where impacts could be seen instantly. Using the SUSAT (reticle is a single triangular post), point of aim was point of impact with the scope set on the 300 meter Battle Sight Zero setting. To adjust for further distances, the shooter must manipulate the dial to the correct yard line. Adjustments go up to 800 meters and there are peep hole iron sights on top of the scope while the Trijicon and Elcan optics, a Ruggerized Miniature Reflex (RMR) sight is present. To gain proper eye relief the shooter must place his eye more or less on the scope. And what of scope bite? On the SUSAT there is a rubber fitting that prevents any. With about an inch of relief of the soldier shooting the author’s M4/M203, there was a slight learning curve because this rubber ring isn’t on an RCO (Rifle Combat Optic).

The Grip Pod was useful but the author’s personal opinion on the Grip Pod is quite negative, nothing to do with the L85A2 but his own experiences with it as a Marine. It’s too large/bulky as a grip and too fragile as a bipod. It’s great for resting the weapon, but using it as a legitimate field bipod in the rough, unforgiving environment of a firefight or truly rough range use, the author found it too fragile. The legs had a tendency to snap under pressure.

Operating the SA80 is rather straightforward but a little awkward if someone is very M16/M4 controls minded. To chamber a round, the shooter must first insert the magazine. Being a bullpup, this is a different affair than an M16/M4. British doctrine dictates that the right hand must always be on the pistol grip, a very sound principle realizing that Marines have the same one but in using an M16/M4 sometimes one must use his right hand for manipulation. Tilting the rifle to the right, the shooter inserts a magazine, then tilting it the opposite direction to the left, the shooter then charges the rifle with the left hand on the cocking knob. There is no left handed configuration; all recruits are trained to be right handed with the rifle. A good tap is then required when the knob has gone fully forward, similar to tapping the forward assist on an M16/M4. Here is an issue from a tactical perspective; most of this requires the shooter to break his hold to the target, even if he is physically looking at the target, the rifle must be tilted this way and that and is not pointed where he is looking. Unlike M16/M4s where a shooter can complete most operations without even breaking a cheek wield. Of course after much training and familiarization a shooter could get to a point where he could manipulate the rifle fast enough to get it back up in the case of a stoppage or empty magazine.

For immediate action procedures, the British SOP (Standard Operating Procedure) is advantageous over the Marine one. Since basic training many Marines have it drummed into their heads the phrase “Tap, Rack, Bang” when dealing with a misfire. In technical terms, this means to tap the bottom of the magazine with the free hand, rack the charging handle to the rear, and then attempt to fire. This is an excellent remedy apart from one often-omitted necessary step. An instructor will always be sure to teach that immediate action requires; observe for feeding and ejecting, then move to “Tap, Rack, Bang.” The British procedure cuts to the source of the malfunction; if encountering a stoppage, tilt the rifle to the left, retract the charging knob and view the chamber. This immediately forces the shooter to confront the malfunction. It may just be an empty magazine or it may be a double feed, but the point is the shooter is looking directly at the problem instead of possibly making it worse by executing “Tap, Rack, Bang.”

Firing the L85A2 is just like any bullpup, the largest obstacle is the trigger. The trigger itself does not have a heavy pull; it is a two stage military trigger with slack taken up about 2/3 of the way back. The issue is the reset time. A shooter has to almost release his finger the entire length of travel for the trigger to reset to the hammer in order to get off the next shot. If the reset has not completed, that next shot cannot be made until the trigger is released the full length. Once again, with constant training this issue will go away, but from a shooters perspective, studying the rifle in general, the author found the trigger to be lacking.

When the bolt is locked to the rear after the last round, the charging knob is visibly locked to the rear in the corner of the shooter’s right eye. This was a comfort compared to an M16/M4 where if a shooter is not carefully paying attention to the vibrations of the rifle, he can miss sensing the bolt lock back after the last round. The bolt locking levers are on both sides of the weapon, truly convenient compared to the M16/M4 where the release catch is only on the left side. Similar to a Tavor, the release catch can be depressed by the same hand that inserts a fresh magazine.

Also fired was the 9x19mm Glock 17, now in service as the primary sidearm (secondary being the SIG Saur P226) to replace the FN Hi Power (there are still a few Hi Powers in use on Bastion, mostly with rear echelon troops). The handgun itself was a standard Glock 17. Thus, the Glock will not be reviewed as its reputation is world renowned. But what is different are the operating procedures and holster. As a side note, the course of fire with a pistol involved a kneeling position, which is different from the Marine Corps’ pistol course, which is all standing.

Within the U.S. Armed Forces, the Beretta M9’s safety conditions are set upon the pistol, with magazine inserted, safety on, and round in the chamber all various safety measures. But with no external safety on the Glock, the British have to improvise. With a magazine inserted, no round in the chamber, the pistol inserted in the holster is itself considered a safety feature. Once drawn, the pistol has now been raised to an elevated safety level, racking the slide brings it to the final condition before firing. Inserting the pistol back in the holster brings the condition back down.

The holster in use is certainly a wise choice. When the MoD (Ministry of Defence) adopted the Glock 17, it also adopted the Radar 1957 (listed as 6661 Safe & Fast Index holster) Level 3 holster set as well. This is a small company that has its product made in Italy. In comparison to the U.S. equivalent, the BlackHawk! SERPA, the Radar offers some distinct advantages. The UK also issues SERPA holsters but only for soldiers armed with the SIG Sauer P226. The reason behind comparing the Radar 1957 to BlackHawk! specifically and not Safariland or other holster brands in use is because service wide, the SERPA is the most thoroughly issued out and used personally by those with Berettas signed out to in the U.S. Armed Forces.

Both holster systems are designed to have rotating angles of draw and both are made in sets with different cradles intended for thigh, hip, and chest/flak mounted carry. This is to facilitate wearing the pistol in a garrison setting without body armor on. But if the user dons his flak, he can easily transition his holster from a thigh/hip mount to a flak mounted one, as some prefer to have the handgun high up on their chest while burdened down with gear. This makes for drawing a handgun in confined spaces such as in the turret of an American MRAP or British Foxhound more accessible. The difference between these two locking systems is quite noticeable; the Radar 1957 is much more robust than the SERPA. The Radar 1957s locking cradle is permanently attached to the mount, and the holster locks in via a built up circular device. The SERPA on the other hand, is held in place by two rotating pieces of plastic in its cradle. The cradle is secured to the mount via three Phillips head screws.

In retention though, SERPA is faster in drawing; it already has a good reputation and that is primarily what it is based on and founded upon. This retention system is dependent on a single swivel that locks the trigger guard into place; otherwise no other lock is present. The swivel is also about the size of a quarter. The holster is also very exposed with the muzzle portion completely open. The Radar’s retention system is a two stage. The first is activated by the firing hand thumb to release the slide lock and the second is operated by the trigger or middle finger to release the pistol itself. Although slower initially, with training the speed can be brought up to that of the SERPA. The Radar 1957 also exposes the pistol less and is a two stage retention system but most of the pressure is more on the shooters middle finger. Instead of the SERPA, all the pressure is on the trigger finger during the draw. From a safety perspective, this is perfect, one can draw the Radar all day without worrying about a negligent discharge; but although the SERPA is quick, the retention isn’t as impressive.

At the conclusion of the shoot, the author was extremely satisfied having gained valuable experience shooting and learning about his counterpart’s weapon systems. But more importantly he was learning about how another military operates different from his own, because the second you stop learning is the second you start dying.

By Todd Burgreen

Adams Arms has sought to engineer a complete solution to the deficits they felt are found in the direct impingement AR family of rifles and carbines. Adams Arms was an early innovator in the piston AR surge; even offering piston retro fit kits for direct impingement ARs. The principle improvement offered by the Adams Arms gas piston system comes from eliminating the venting of hot, carbon-laden gases into the receiver and bolt carrier group. This reduces the cleaning requirements associated with direct gas-impingement ARs. It also means the bolt carrier group and associated springs are not subjected to the searing heat of the tapped gasses; this being one of the major causes of small parts failure. Other attention to detail components further round out the Adams Arms EvoLite rifle evaluated in this article such as Mil-Spec forged 7075-T6 upper and lower receivers Type III hard coat anodized with beveled magwell, M4 feed ramps, 1913 Picatinny rail flat top with dry lube internal finish and laser engraved T-markings. An Ark Defense adjustable buttstock, trigger, Ergo pistol grip, and Samson Evolution free float light weight modular rail system with two 2-inch rail sections flesh out the EvoLite.

The Adams Arms EvoLite focuses on providing an accurate well handling light weight piston driven AR that is controllable during rapid shot strings while maintaining reliability. This is accomplished through design intent, fit/finish, sights, trigger, and barrel. Adams Arms starts with their Ultra Lite Voodoo 14.5 inch 1:7 barrel. This 4150 CMV (Chrome Moly Vanadium) is precision honed with special attention paid to the gas vent hole. A VDI Jet Comp is permanently affixed to the 14.5 inch barrel allowing it to be considered a rifle versus an NFA short barrel rifle (SBR). Adams Arms then incorporates their patented mid rifle length inverted adjustable gas piston system. The longer dwell time offered by mid length piston allows for a smaller gas port minimizing the amount of energy being applied to the piston to cycle a round. All these things add up to a soft recoil pulse as touted by Adams Arms.

Adam Arms’ ARs have from the beginning addressed reducing carrier tilt, cam pin wear and carrier bounce. Proponents of piston-driven ARs point to greater reliability in adverse conditions and less reliance on routine maintenance compared to the direct impingement operating method. At the heart of the short stroke gas operating system is an operating rod, three-position gas block and forward venting gas plug that retains the piston. The piston can be accessed through the front of the gas block without removing the handguard so optical sights or laser devices do not need to be zeroed after routine maintenance. Adam Arms’ piston system uses a port on the barrel to tap gas to operate their inverted gas piston. The tapped gas is directed into a drive rod sleeve. The gas is harnessed inside the drive rod sleeve and pushes the bolt carrier rearward via an operating rod using the gas pressure to cycle the action. Total forward and rearward movement of the piston is approximately 1/2 inch. Once the action is cycled the remaining gases are pushed out of the front of the gas block, purging and cleaning the system while keeping the gases out of the face of the user and the receiver. The Adams Arms gas piston components and gas block are Melonite treated and the bolt carrier is ion bonded for increased parts endurance. All of the parts that operate the rifle come with a lifetime warranty. The Adams Arms gas block has three settings – normal, suppressed, and closed/single shot. With this said, the pinned flash Jet Comp on the EvoLite limits options in terms of adapting over to a suppressor. Other Adams Arms rifle models take full advantage of the suppressor capability. The Adams Arms EvoLite weighs less than 7 pounds and measures 32 inches stock fully collapsed and 35.25 inches extended.

It was crucial to verify functioning reliability with the Adams Arms EvoLite. A variety of 5.56mm and .223 Rem rated ammunition was tested from Black Hills, Federal, Hornady and Winchester. No reliability issues were encountered. Accuracy test protocol consisted of three 5-shot groups with each ammunition type. Velocity figures ranged from 2,600 fps to 2,800 fps over a RCBS chronograph from the 14.5 inch barrel. For this evaluation, a Meopta Meostar R2 1-6x was mounted on the EvoLite to assist in determining the rifle’s intrinsic accuracy. The EvoLite kept all loads tested at 2 inches or better at 100 yards included the Federal XM193 55gr FMJ and Winchester 55gr FMJ. This accuracy level will justify too many leaving a magnified optic such as Meopta MeoStar R2 1-6x scope. This scope selection is certainly not that common or well known to many shooters.

Most have no idea what they are missing in terms of rifle scope optics offered by Meopta. Many in our community hold strongly to preconceived notions regarding rifle scope optics. There are times when one must get past these comfortable set beliefs to truly appreciate what another product may offer. Granted, we all deal with budget pressures either as individuals or as a work entity. This does not change performance ratings; only what we are willing to pay for to best get the job done. Meopta optics may be beyond reach either for reasons of economics, more pressing equipment needs, or upon reflection, a lack of understanding of what Meopta offers in terms of capabilities. Meopta is a leading European and American optics manufacturer that has been in existence since 1933. Meopta produces one of the most diversified high performing line-ups of rifle scopes on the market. The new 30mm MeoStar R2 1-6×24 RD is not only the first in the R2 line, but also Meopta’s first riflescope with a 6x zoom ratio. The true 1x magnification, wide field of view, edge-to-edge clarity and illuminated reticle options allow for extremely fast and accurate target acquisition. The versatile Meopta R2 is also excellent for close quarter situations on an AR platform and much longer shots depending on the caliber being used and the shooter’s proficiency.

Another optic choice for the EvoLite, and one that would be considered more “standard” in comparison to the Meopta R2, would be the Aimpoint T1 red dot sight. The T1 is superior in facilitating engaging targets at close distances with the red dot easy to pick up rapidly. The Aimpoint T1 red dot sight offers the capability to engage multiple targets in rapid sequence compared to open sights, while at same time providing adequate accuracy out to a couple hundred yards. This is due to the red dot superimposing an aim point on the target while not totally obscuring the target due to the dot not being that large. As many “maturing” shooters can attest to the single focus plane with the red dot is easier to shoot accurately than coordinating front and rear sights.

The T1 weighs 4 ounces including the quick detach mount used. The Aimpoint T1 is one of the most durable red dots available and features the longest lasting battery on the market and it has an adjustable intensity 4 MOA dot. Aimpoint uses a special coating that only reflects the red dot’s specific frequency of light allowing almost 100% of all other radiation straight through, which provides superior clarity for both daylight use and if night vision devices are employed. The Aimpoint T1 has 12 intensity settings – 4 night and 8 daylight.

A US Palm (US Primary Armament Logistical Manufacturing) Agile Combat System (ACS) chest rig/plate carrier with High Speed Gear “Taco” pouches affixed was used in evaluating the Adams Arms EvoLite. US Palm is a company helping equip our military, law enforcement, and private security contractors (PSC) as well as not forgetting/ignoring civilians. The ACS plate carrier evolved out of US Palm’s Desert Tracker and Ronin plate carriers and ingeniously allows for the combining of several different US Palm products to create the ACS that best suits individual needs. The ACS evaluated for this article joined the US Palm Hardened Back Pack (HBP) with Desert Tracker Plate Carrier (DTPC) via the U.S. Palm Enhanced Harness System (EHS) “horse collar” shoulder straps. The HBP pack is a small assault pack with a dedicated internal pocket designed to hold ballistic armor, while maintaining utility as a pack. The HBP also accommodates a hydration bladder. A multitude of MOLLE panels allows you to adapt the HBP to any mission need. The HBP is made from 1000d Cordura and measures approximately 18 inch x 14 inch x 6 inch adding up to a listed 1,800 cubic inches of storage. The front plate carrier panel can be configured any way a user wants thanks to its own MOLLE panels with magazine pouches or other gear selection. This is how the HSG “Taco” pouches were incorporated. The HSG magazine “Taco” pouch allows for multiple types of magazines to be utilized without having to switch out – a very convenient feature.

Both the HBP pack and front carrier can be fitted with either hard or soft armor depending on user preference and mission profile. US Palm developed the ACS around rapid “plug-and-play” mission driven adaptation. As stated by US Palm, “Things change, and you’re trained to adapt – your gear should too.” This is what drove the R&D for the ACS. The ACS’s modularity allows mission specific US Palm components to be combined along with choosing a level of ballistic protection that always has an impact on weight. If you are riding or flying to contact or patrolling, it has an effect on how you load out. The increased protection associated with Level III and Level IV armor comes at the expense of weight and greater rigidity in armor construct. Even in the best condition this increased weight affects operator performance and efficiency; the degradation in performance is further enhanced if the individual does not utilize a properly designed armor and plate carrier system.

Initial impression of the EvoLite was favorable based on handling and feel from the box. There is a reason why the M4 profile AR is preferred by our troops who get a voice in the matter. What is not to like with a lightweight, compact, reliable, well handling rifle? While the EvoLite’s standard trigger was serviceable with a pull weight over 6 pounds, it was decided to take advantage of an opportunity presented by installing a Tactical Fire Control Tac-Con 3MR Trigger. Much of the buzz surrounding the Tac-Con 3MR Trigger System is its three modes/positions of operation. The modes are Safe (selector horizontal at 9 o’clock), Match-grade Semi-Automatic (selector vertical 12 o’clock), and the Tac-Con patent pending 3rd Mode of operation (selector horizontal at 3 o’clock). The 3rd mode provides an alternate type of positive reset that reduces split times between shots. The positive reset characteristic is achieved by transferring the force from the bolt carrier through the trigger assembly to assist the trigger back onto the front sear enabling split times that rival automatic rates of fire once familiarized with operation. Both semi and 3rd mode positions feature a non-adjustable 4.5 pound trigger pull weight with zero over travel. The drop in Tac-Con 3MR trigger is simple to install by anyone with rudimentary AR maintenance skills taking only a few minutes and instantly enhances shooter to rifle interface. The only nuance needed is to tilt the trigger group up while sliding under the Tac-Con provided safety lever. Tac-Con designed the 3MR not as a finicky fragile match trigger, which can be less than hardy under robust conditions, but rather as single stage 4.5 pound trigger with a short reset suitable for all conditions of use. The Tac-Con 3MR meets or exceeds military specifications for drop safety –something that “match” triggers usually can not represent as doing. All in all, the 3MR allows for multiple rounds to be sent downrange quickly/accurately and for precise longer range shot placement better than your standard trigger unit; yet retains reliability lacking from some of the other trigger units on the market.

It was decided to expand normal T&E protocol by running both the Meopta R2 and Aimpoint T1 through Echo Valley Training Center’s (EVTC) 360 and “Jungle Walk” ranges. Training scenarios involving team tactics along with patrolling to contact allowed the Adams Arms EvoLite to shine in terms of potent firepower and accuracy, especially when augmented with the Tac-Con 3MR trigger. No surprise with the pros and cons of the two different sights. The Aimpoint T1’s red dot is not dependent on a specific eye relief distance to be effective in accurately placing rounds on target in a rapid fashion. Firing from unorthodox positions while working around range vehicles showed why the light weight EvoLite combined with the Aimpoint T1 is such an effective combination. The Meopta R2 enabled target identification and more precise fire. Close range engagement of targets is still a viable proposition with the R2; just not as seamless as the Aimpoint T1. The Meopta MeoStar R2 1-6x is a combination of a red dot optic and magnified scope. It was developed for use at short and medium distances. With a low magnification setting the illuminated dot inside the reticle can be used like a red dot sight. The Meopta MeoStar’s variable magnification settings allows CQB speed at lowest power setting and enough magnification to make headshots at 200 yards or more. The illuminating unit offers eight illumination stages for the use in broad daylight no matter the background. Conversely, the T1 can place accurate fire at greater distance than anticipated for a non-magnified optic; obviously not as precise as a 1-6x scope like the Meopta R2. However, not being a prisoner to a defined eye relief distance offers a certain advantage.

While the Adams Arms EvoLite is not going to be issued to our military services or law enforcement agencies, civilians could easily consider using the rifle for multiple roles. There are an overabundance of AR style rifles vying for consumer attention. The EvoLite is worthy of consideration based on attention to detail and quality of materials used in its manufacture. The cliché of buy right the first time comes to mind with the Adams Arms EvoLite being a good example.

Sites of Interest

Adams Arms
www.adamsarms.net

Meopta U.S.A., Inc.
www.meopta.com

Tactical Fire Control, Inc.
www.tacfirecon.com

Aimpoint Inc.
www.aimpoint.com

Echo Valley Training Center
www.echovalleytrainingcenter.com