By The Small Arms Review Editorial Staff

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Faxon Firearms

Model: ARAK-21
Species: AR-Compatible Upper Receiver & Complete Rifle
Manufacturer: Faxon Firearms
Website: www.faxonfirearms.com
NRA Show Booth Number: 2458
Caliber: 5.56 NATO, 300 BLK, & 7.62×39
Russian (Others Coming)
Overall Length Standard
Model, Stock extended: 32” w/ 16” Barrel (Folding Stock Compatible)
Barrel Lengths Available: 12.5”, 16”, 20”
Weight, Standard Model: 7.5 lbs, Unloaded (XRS Rifle)
Rate of Fire: ~1150 RPM (Cyclic)
MSRP: $1199 (Upper Only), $1899 (XRS Complete Rifle)

AR-15 + AK-47 = ARAK-21. The ARAK platform is a self-contained, long-stroke, fully ambidextrous, multi-caliber upper receiver compatible with all mil-std AR-15s. With a monolithic upper rail, adjustable gas, and either right of left-hand ejection, the ARAK is a heavy-duty ready platform for any need.

Model: Houlding Wraith
Species: AR-15
Manufacturer: Houlding Precision by Faxon Firearms
Website: www.faxonfirearms.com
NRA Show Booth Number: 2458
Caliber: 5.56 NATO
Overall Length Standard Model, Stock extended: 33” w/ 16” Barrel & Carbine Carbon Fiber Stock
Barrel Lengths Available: 16” and 18”
Weight, Standard Model: 6.0 Lbs, Unloaded
Rate of Fire: ~800 RPM
MSRP: $1199 (Upper Only), $1899 (XRS Complete Rifle)

The perfect balance of precision, machining, performance, and versatility. The Houlding Wraith features a 15” carbon fiber handguard (full M-LOK compatibility) along with a carbon fiber stock for quick handling and a svelte allure. Featuring Faxon’s renowned FLAME barrels, the Wraith puts rounds downrange fast, accurate, and in-style.

DoubleStar

Model: STAR 10B
Species: AR-10
Manufacturer: DoubleStar
Website: www.star15.com
NRA Show Booth Number: Booth 4409
Caliber: .308
Overall Length Standard Model, Stock extended: 41”
Barrel Lengths Available: 18”
Weight, Standard Model: 9.8 lbs
Rate of Fire: Semi-Auto
MSRP: $2566.69

DoubleStar’s new STAR10-B™ in .308 merges supreme accuracy, unfailing reliability and blazing-fast operation. Destined to rule the range, match and hunting field, the STAR10-B™ elevates the power and precision of the AR-10 platform to a new level. Featuring a billet upper and lower receiver, ACE™ Hammer™ stock and Bullseye™ muzzle brake, this beast is a real heavy hitter.

Model: Always Ready
Carbine (ARC)
Species: AR-15
Manufacturer: DoubleStar
Website: www.star15.com
NRA Show Booth Number: Booth 4409
Caliber: 5.56
Overall Length Standard Model,
Stock extended: 35.5”
Barrel Lengths Available: 16”
Weight, Standard Model: 6.8 lbs, unloaded
Rate of Fire: Semi-Auto
MSRP: $1370.74

Everything changes over time including your patrol rifle. New for 2016 is the ARC™ (Always Ready Carbine™). Starting with a 16” lightweight, Nitride barrel wrapped with a 15” Samson Evolution handguard for the ability to put rails where you need them. An Ergo Sure Grip ensures a sturdy grasp and the ACE™ Socom™ stock is designed with door breaching in mind. The ARC™ comes equipped with Samson Manual Folding Front and Rear sights.

Ohio Ordnance Works, Inc.

Model: H.C.A.R. (Heavy Counter Assault Rifle)
Species: Tactical BAR
Manufacturer: Ohio Ordnance Works, Inc
Website: http://www.ohioordnanceworks.com/hcar
NRA Show Booth Number: 6047
Caliber: .30-06
Overall Length
Standard Model, Stock extended: 38.25 in. (16” Barrel); 42.25 in. (20” Barrel)
Barrel Lengths Available: 16”/20”
Weight, Standard Model: 11.75 lbs. (16” Barrel); 12.5 lbs. (20” Barrel)
Rate of Fire: Semi-automatic
MSRP: $4,399.99

The H.C.A.R. combines the best of Browning’s ideas, today’s tactical options and accessories, and cutting edge engineering to deliver the most versatile .30-06 weapon system to date:

Rugged 8620 steel receiver is relief cut for weight reduction
Flat-top picatinny rail allows custom optic choices and back-up sights
Industry standard 5/8-24 barrel thread allows for flash suppressor/muzzle brake
Hand-guard’s four picatinny rails provide abundant accessory options
Includes thirty-round, high capacity magazines
For MORE visit: www.ohioordnanceworks.com/hcar

POF USA

Model: Renegade (+)
Species: AR-15
Manufacturer: Patriot Ordnance Factory
Website: POF-USA.COM
NRA Show Booth Number: 2753
Caliber: 5.56 NATO
Overall Length Standard Model, Stock extended: 33.5” Collapsed/37.5” Extended
Barrel Lengths Available: 16.5” Barrel
Weight, Standard Model: 6.4 lbs
Rate of Fire: Semi-Auto
MSRP: $1,899.99

What really sets the Renegade + apart is the Gen 4 POF-USA billet lower receiver and POF-USA Ultimate Bolt Carrier Group. This receiver is completely ambidextrous and includes our flat 3.5lb match grade trigger with KNS Precision anti-walk pins – match ready right out of the box. The magic in the upper receiver is held within our Ultimate Bolt Carrier Group. NP3 coated for maximum protection & reliability, integrated gas key and the POF-USA Roller Cam Pin upgrade installed from the factory. If there ever was a direct impingement rifle that exceeds all expectations, the Renegade + is it.

CZ

Model: CZ 805 Bren S1 Carbine
Manufacturer: CZ-USA
Website: cz-usa.com
NRA Show Booth Number: 2759
Caliber: .223/ 5.56×45
Overall Length Standard Model, Stock extended: 39”
Barrel Lengths Available: 16.2”
Weight, Standard Model: 8.02 lbs
MSRP: $1,999

The Bren is now available in carbine form with a 16.2” barrel. Equipped with the factory’s folding adjustable stock, it also has a new set of flip-up adjustable iron sights. Chambered in .223/5.56 and using the ubiquitous STANAG magazine from the AR16/M16, it easily accepts optics and lights on its top and bottom Picatinny rails. An effective two-port muzzle brake helps keep the Bren solidly on target and reduces recoil and muzzle flip.

Model: CZ Scorpion Evo 3 S1 Carbine
Manufacturer: CZ-USA
Website: cz-usa.com
NRA Show Booth Number: 2759
Caliber: 9mm
Overall Length Standard Model,
Stock extended: 34.75”
Barrel Lengths Available: 16.2”
Weight, Standard Model: 6.1 lbs
MSRP: $999

Available in two variants, the Scorpion Carbine is a whole new animal. Building on the lauded submachine gun platform that first hit the US civilian market in pistol form in 2015, the Carbine has a 16.5” barrel fitted with either a two-port compensator or a faux suppressor built specifically for CZ-USA by SilencerCo. Fit with the factory’s folding adjustable stock, the Carbine features a number of US-made parts to make it fully 922(r) compliant. The newly-designed forend, covered in M-LOK attachment points keeps the profile slim while still big enough to swallow most pistol-caliber suppressors.

Ruger

Model: 8500
Species: Ruger AR-556
Manufacturer: Ruger
Website: http://www.ruger.com/products/ar556/models.html
NRA Show Booth Number: #: 4323
Caliber: 5.56 NATO/ 2.23 REMINGTON
Overall Length Standard Model,
Stock extended: 35.50”
Barrel Lengths Available: 16.0”
Weight, Standard Model: 6.5 lbs
Rate of Fire: Semi-automatic
MSRP: $799.00

The American-made direct impingement Ruger AR-556™ features forged 7075-T6 aluminum upper and lower receivers and a cold hammer-forged chrome-moly steel barrel with M4 feed ramp cuts. The AR-556’s carbine-length, flat-top, M4 design includes Ruger® Rapid Deploy folding rear sight, milled F-height gas block with post front sight, forward assist, dust cover, and brass deflector. Other features include a telescoping six-position stock, improved trigger-reach grip, enlarged trigger guard and one 30-round Magpul® PMag®.

DRD Tactical

Model: CDR15
Species: QUICK TAKE DOWN AR15 TYPE RIFLE
Manufacturer: DRD TACTICAL
Website: WWW.DRDTACTICAL.COM
NRA Show Booth Number: NA
Caliber: 5.56 NATO & 300BLK
Overall Length Standard Model, Stock extended: 34.5”
Barrel Lengths Available: 7.5”, 10.5” & 16”
Weight, Standard Model: 6.8 LBS
Rate of Fire: SEMI-AUTO, FULL AUTO(GOV SALES ONLY)
MSRP: $2091

DRD TACTICAL Designs and manufactures patented quick take down rifles in 5.56 Nato, 300BLK, 7.62 Nato, 6.5 Creedmore, 6.5×47 Lapua and 338 Lapua calibers.

Perfect for easy transport/travel in brief case or back pack for that long hunt. All DRD rifles are made with USA made components.

556 Tactical

Model: SPR (Special Purpose Rifle)
Species: AR-15
Manufacturer: 556 Tactical
Website: www.556tactical.com
Caliber: .223 Wylde Match
Overall Length Standard Model, Stock extended: 35”-38.5”
Barrel Lengths Available: 18”
Weight, Standard Model: 6lbs 7oz
Rate of Fire: Semi – automatic
MSRP: $1,595.00

Model: Stryke-X
Species: AR-15
Manufacturer: 556 Tactical
Website: www.556tactical.com
Caliber: .223 Wylde Match
Overall Length Standard
Model, Stock extended: 33”-36.5”
Barrel Lengths Available: 16”
Weight, Standard Model: 6lbs 7oz
Rate of Fire: Semi-Automatic
MSRP: $1695.00

We at 556 Tactical LLC are pleased to release our Stryke-X and SPR rifles. Both feature our match grade 416R stainless 1:7 twist .223 Wylde barrels in 16” Hex Fluted (Stryke-X) and 18” Standard Fluted (SPR). We guarantee under 3/4 MOA accuracy using match grade ammo. Free float rail systems, competition triggers, and muzzle brakes, helps you stay on target faster, longer, and comfortably.

Beretta

Model: ARX100
Species: ARX100
Manufacturer: Beretta USA Corp.
Website: www.beretta.com
Caliber: Booth #5222
Overall Length Standard Model, Stock extended: 5.56mm
Barrel Lengths Available: 35.75″
Weight, Standard Model: 16″, 10.25″
Rate of Fire: 6.8 LBS
MSRP: Semi Automatic
MSRP $1,950

The ARX100 takes the concept of a modular rifle to new levels, while maintaining an absolutely simple operation that make it ultra-reliable. With ambidextrous controls and ejection, easily-replaceable cold hammer forged barrel, lightweight polymer construction, and virtually endless possibilities for customization, the ARX100 is adaptable to any firing scenario and is perfect for today’s most demanding tactical shooter.

Battle Arms Development

Model:   BAD556-LW
Species: (AR-15, etc.)  AR-15
Manufacturer:  Battle Arms Development, Inc.
Website:     www.battlearmsdevelopment.com
SHOT Show Booth Number:  6206
Caliber:  .223 Wylde
Overall Length Standard Model, Stock extended:  33.75″
Barrel Lengths Available:  16″ Standard (7.5″, 10.5″, 14.5″, 16″, 18″)
Weight, Standard Model:  5.5 lbs (without sights/optics & mag)
Rate of Fire:  750rds/min
MSRP: $3,350

Model:   BAD-PDW
Species: (AR-15, etc.)  AR-15
Manufacturer:  Battle Arms Development, Inc.
Website:     www.battlearmsdevelopment.com
SHOT Show Booth Number:  6206
Caliber:  Multi / .223 Wylde
Overall Length Standard Model, Stock extended:  21″ Collapsed to 26″ Extended
Barrel Lengths Available:  7.5″ (10.5″, 14.5″, 16″ available)
Weight, Standard Model:  Approx. 6lbs w/o Optics and Mag
Rate of Fire:  750rd/min
MSRP: $2,800 (without sights or optics)

Battle Rifle Company

Model: BR4 SPECTRE
Species: AR15 Style Rifle
Manufacturer: Battle Rifle Company
Website: www.battleriflecompany.com
NRA Show Booth Number: 2911
Caliber: 5.56mm, also available in 6.8 and 300 blackout 
Overall Length Standard
Model, Stock extended: 37 inches
Barrel Lengths Available: 11.5, 14.5 16 inches
Weight, Standard Model: 6.7lbs
Rate of Fire: Semi- 200 rpm
MSRP: $1195.00- 1295.00 in FDE

The BR4 SPECTRE is our free float version of our combat rifle. It is the #1 rifle we sell to Law Enforcement. The Extended rail allows for more area to attach lights, laser and optics. It’s tough construction allows it to stand up to the rigors of daily use and comes with features like ergo grips, over molded stock and single point backplate. Cost effective and full featured, this rifle is ready to go.

Model: BR4 TRIDENT
Species: AR15 style rifle
Manufacturer: Battle Rifle Company
Website: www.battleriflecompany.com
NRA Show Booth Number: 2911
Caliber: 5.56mm
Overall Length Standard Model, Stock extended: 37 inches
Barrel Lengths Available: 10.5, 16 inch
Weight, Standard Model: 6.6 lbs
Rate of Fire: Semi 200rpm
MSRP: $1595

The BR4 TRIDENT is our rifle specifically designed for Maritime Security (MARSEC) operations. Designed from the ground up to withstand months on the open water it’s lightweight and practical for its intended application. Specifically designed for wet weather operations, this rifle is perfect for Coastal Operations, Riverine Operations, for Service on Islands and working in a fish and game environment.

Armalite

Model: M-15™ LTC 16
Species: M-15™ (AR-15)
Manufacturer: Armalite
Website: www.armalite.com
NRA Show Booth Number: 5447
Caliber: 5.56x45mm / 7.62x39mm
Overall Length Standard Model, Stock extended: 35.3”
Barrel Lengths Available: 16”
Weight, Standard Model: 7lbs
Rate of Fire: Semi Auto
MSRP: $999 / $1099

New for 2016, Armalite’s Light Tactical Carbine provides shooters with a durable, hard-hitting, modern sporting rifle in a streamlined and affordable package. With features like Armalite’s own free-floating tactical KeyMod handguard and low profile gas block, the LTC carries a modern profile in a light & scalable package. Weighing in at just 6 pounds, the M15LTC16 is the perfect choice for anyone appreciating simplicity, value, quality, and up-to-the-minute features in their AR. Also available in 7.62x39mm and 6.8SPCII configurations.

Model: AR-10® PRC-260
Species: AR-10®
Manufacturer: Armalite
Website: www.armalite.com
NRA Show Booth Number: 5447
Caliber: .260
Overall Length Standard Model, Stock extended: 41.3”
Barrel Lengths Available: 20”
Weight, Standard Model: 11.4lbs
Rate of Fire: Semi-Automatic
MSRP: $3500

The all-new Armalite AR-10® PRC-260 is designed to be the ultimate semi-automatic precision rifle on the market. Using technology developed in partnership with Surgeon Rifles and AWC Silencers, this precision rifle offers a consistency in suppressed and unsuppressed configurations that aren’t available anywhere else. A proprietary selectable gas block makes optimization for suppressed or unsuppressed applications a breeze. The Giessele Two Stage trigger provides crisp trigger pulls and reset that you expect out of a precision rifle.

*Image shown includes optional Cerakote and optional AWC Suppressor, available at an additional cost.

YHM

Model: YHM-8030 – 300 Blackout Pistol
Species: 300 Blackout Pistol
Manufacturer: Yankee Hill Machine
Website: www.yhm.net
http://yhm.net/300blk-pistol.html
NRA Show Booth Number: 5940
Caliber: 300 BLK
Overall Length Standard
Model, Stock extended: 14”
Barrel Lengths Available: 9.1”
Weight, Standard Model: 5lbs
Rate of Fire:
MSRP: $1,205.00

The YHM .300 BLK Pistol comes standard with a Phantom Flash Suppressor. The firearm incorporates our KR7 Carbine Keymod Handguard that bridges the gap between the upper receiver and handguard for a seamless look. It also is “T” marked for position on the top rail.

Model: YHM-8309 – 9mm KR7 Carbine
Species: 9mm AR
Manufacturer: Yankee Hill Machine
Website: www.yhm.net
http://yhm.net/9mm-kr7-carbine.html
NRA Show Booth Number: 5940
Caliber: 9mm
Overall Length Standard
Model, Stock extended: 36”
Barrel Lengths Available: 16”
Weight, Standard Model: 6.75lbs
Rate of Fire:
MSRP: $1,400.00

The light recoil of the 9mm KR7 makes it a sound choice for new shooters or those looking for self-defense applications. The velocity of and accessibility of 9mm ammunition also makes this a solid and economical choice at the range. This firearm incorporates our KR7 Mid-Length Keymod Handguard that bridges the gap between the upper receiver and handguard for a seamless look. It also is “T” marked for position on the top rail.

Model: YHM-HRC-160 – Camouflage Hunt Ready Carbine
Species: AR
Manufacturer: Yankee Hill Machine
Website: www.yhm.net
http://yhm.net/5-56mm-camouflage-hunt-ready-carbine.html
NRA Show Booth Number: 5940
Caliber: 5.56mm
Overall Length Standard
Model, Stock extended: 36”
Barrel Lengths Available: 16”
Weight, Standard Model: 7.5lbs
Rate of Fire:
MSRP: $1,531.00

YHM Hunt Ready Carbines arrive ready right out of the box. Not only are they coated nearly completely in RealTree AP ®, but they arrive sighted in at 100 yards so all you have to worry about is buying the ammunition. The Hunt Ready brings the comfort, ergonomics and control of the AR15 family of rifles into the realm of hunting. Each rifles comes standard with a Grovtech padded sling and Busnell scope.

Cobalt Kinetics

Model: EDGE
Species: AR-15
Manufacturer: Cobalt Kinetics
Website: cobaltkinetics.com
NRA Show Booth Number: 2307
Caliber: 223 wylde
Overall Length Standard Model, Stock extended: 36.25”
Barrel Lengths Available: 16” or 14.5” custom ordered
Weight, Standard Model: 6.9 lbs
Rate of Fire: Semi
MSRP: $2,995.00

The Cobalt Kinetics B.A.M.F. EDGE is a reckoning on the AR15. Cobalt has not simply enhanced the performance but instead reinvented it. When you pick up the EDGE you will immediately feel the quality of machining from butt stock to the compensator. Cobalt has incorporated their Dual Drop technology into the rifle for even faster performance. You are guaranteed sub M.O.A. right out of the box.

HK

Model: MR556A1
Species: Semi-automatic Rifle
Manufacturer: Heckler & Koch
Website: www.hk-usa.com
NRA Show Booth Number: 3215
Caliber: 5.56mm
Overall Length Standard Model, Stock extended: 33.90–37.68 in
Barrel Lengths Available: 16.5 in.
Weight, Standard Model: 9.10 lb
MSRP: $3399

A direct descendent of the HK416, the MR556A1 is a semi-automatic rifle developed by Heckler & Koch as a premium level civilian firearm with match rifle capability. Like the HK416, the MR556A1 is a major product improvement over conventional AR-type carbines and rifles. The MR556A1 uses the HK proprietary gas piston operating system, employing a piston and a solid operating “pusher” rod in place of the gas tube normally found in AR15/M16/M4-style firearms.

Model: MR762A1
Species: Semi-automatic Rifle
Manufacturer: Heckler & Koch
Website: www.hk-usa.com
NRA Show Booth Number: 3215
Caliber: 7.62mm
Overall Length Standard Model, Stock extended: 35.94–39.10 in
Barrel Lengths Available: 16.5 in.
Weight, Standard Model: 9.84 lb
MSRP: $3999

Like its 5.56mm counterpart, the MR762A1 is a direct descendent of the HK417, only in a semi-automatic rifle configuration developed for civilian users. Using the HK-proprietary operating system, the MR762A1 is gas operated and uses a piston and a solid operating “pusher” rod in place of the common gas tube normally employed in AR15/M16/M4-style weapons.

By David Lake

Here is the unlikely success story about a new small arms manufacturer from the desert of Southern Utah. Cobalt Kinetics came from nothing; that is, the founder and partners involved in the inception of the company knew little to nothing about guns or how to make them, or how to sell them. All they really had was vision and motivation; usually enough to ensure success in anything. Cobalt began unencumbered by the financial burden that makes growing a new business difficult; the infrastructure to make this business venture possible came about at the snap of a finger. Free from the mundane struggles and growing pains of starting a new business, the men and women of Cobalt Kinetics were able to move forward at the speed of thought in pursuit of their endeavor. The company’s success was not without cost however. There was much hard work involved, to be sure. The people of Cobalt Kinetics will regale you with stories of 20 hour workdays and 7 day workweeks to get the thing started. Their greatest challenge, and highest achievement, and ultimately the key to their success was the cohesive working relationship among the staff. The machine operators, the executives, and everyone in between shared a common goal. Cobalt’s goal and vision was not to simply package another AR-15 but to create a better AR-15. Sure, the current staple of the Cobalt brand is indeed an AR-15 at its heart. But Small Arms Review was made to understand (and shown, unofficially) that Cobalt’s interpretation of the AR-15 is just a first step. Cobalt Kinetics is scheming to change the industry and they intend to make some waves.

At first look, Cobalt’s flagship rifle, the BAMF (Billet Aluminum Modern Firearm) comes across as an abstract modern art masterpiece. It’s as if Alexander Calder and his contemporaries conspired to craft a rifle. Maybe the BAMF is where gothic architecture meets science fiction space film. This rifle’s shape is more art than engineering. During conception and design, the artist behind the gun was left to draIw and design as he wished (Cobalt really does employ an artist who in fact knows precious little about guns). Cobalt’s engineering team just had to fine tune the artwork until a gun could fit inside. Whatever the cause or effect of its marked appearance, believe that the BAMF is all business. Small Arms Review became aware of Cobalt’s plans in October of 2014. Cobalt expressed some very optimistic plans and goals for the future and direction of the company. They had nothing but a lower receiver and some drawings and, in no more than 10 weeks, Cobalt Kinetics managed to create a full line of rifles and unique features and amazing possibilities. SHOT Show 2015 was the official unveiling of Cobalt and its BAMF.

During its growth, the team at Cobalt never lost sight of the plan to produce a supreme quality AR-15. The internals and all working components are either sourced from top-shelf industry firms or created in-house at Cobalt Kinetics. The BAMF makes neither compromise nor concession for economy’s sake. No expense is spared, as long as that expense directly enhances the rifle’s performance or aesthetic. There are many practical rifles available to the consumer. There are many accurate rifles available to the competitor. There are many hard-working rifles available to the professional. There are beautiful rifles available to the collector. The BAMF is all of these; and available to everyone. The BAMF straddles the thin line that separates form from function. Nay, it erases that line and expresses plainly that form and function can coexist. The trend in small arms development today demands modularity and durability and the tastes of upcoming consumers demand style and exclusivity. Anyone with a background in mechanics or engineering will scoff at the allusion that you can have it all. For example, a Maserati is a work of art – it’s exquisitely sculpted by old-world craftsmen, but it can never run as long or be as reliable as a Toyota, which is built with gross robotic precision. And be sure that Toyota will never make anything as beautiful as the Maserati. So, maybe it’s true, in cars at least- you cannot have it all. But if you’re seeking an AR-15 rifle that is visually pleasing, and functionally superior, you are now in luck. As with all things art, everyone has their taste. If the BAMF does not please your eye, sorry, you should move on. There are plenty of boring, ordinary AR clones on the market.

When looking over the Cobalt BAMF, it’s easy to miss the mechanical genius inside and the beauty is in the details. The BAMF has a totally new and unique operating feature coined the “DD” (double “d”) and it is an ambidextrous forward assist and simultaneous bolt release integrated and incorporated into the upper receiver. The conventional forward assist is mirrored on both sides of the upper. The forward assist buttons have been linked through a secret mechanism in the upper receiver, so each button actuates the other. And this symmetrical forward assist has been linked to the bolt catch in the lower receiver. There are no major changes to the basic function of the AR-15. The system does not require a special bolt group or any modification to any component. It’s a big step forward, without the usual step back. The Double-D offers the user fast (and safe) actuation of the bolt catch after the bolt has locked to the rear on an empty magazine. Once a full mag has been seated into the rifle, the thumb of the strong hand just bumps one of the forward assist buttons to send the bolt home. The result is equal to the extended levers that snake down through the trigger guard with claims to speed up the operation of a rifle. But these devices come with their own kinds of potential problems. Some shooters have been observed to discharge a rifle while attempting to actuate the control lever in the trigger guard. It is the belief, in fact, of every gun-handling professional that the finger should only ever enter the trigger guard with immediate intent to fire the gun. The placement of other optional control surfaces proximal to the bang switch is just a bad idea. The Double-D mechanism serves the same purpose, without exposing the shooter to the possibility of an accident. Also, the forward assist is a familiar part on the AR-15 and a standard part of the AR’s manual of arms, so there’s no need to re-learn or familiarize one’s self with the placement of a new control surface to
operate the rifle.

Cobalt Kinetics would not rest on their laurels when it comes to proving the rifle. Good looks will only get you so far today so they employed a team of men whose daily job requirement was to wear out and destroy the BAMF. For weeks this team loaded magazines and emptied those magazines as efficiently as possible; by pulling the trigger on a rifle. Cobalt burned off over 80,000 rounds of 5.56 NATO through 4 rifles in the name of learning, by way of abusive testing. Two of these rifles have cycled over 30,000 rounds each. Failures happened, sure, but not like one would expect. A gas tube burst as it approached a temperature so high all tensile strength had been lost. One barrel cooked off its ceramic coating. Another barrel changed color turning from bright stainless to purple and brown. Extractor and ejector springs flattened out after taking a set and losing tension from extreme heat exposure. One buffer’s urethane bumper shattered from fatigue. Smoke escaped from all the cracks and gaps as oil and lock-tite were boiled off. The pair of 30,000 round rifles, however, kept the same bolt groups and trigger mechanisms throughout testing. The structural members; the receivers, forearms, stocks and buffer tubes all lasted the duration with no demonstrable wear, failure or other deficiency (the barrels lasted through the entire test, but with little remaining accuracy potential). This month long exercise showed a wanton indifference to the ammunition shortage we’re experiencing today. But what was learned from it is the important part.
Cobalt can authoritatively say what works and what doesn’t. You can wholeheartedly believe that the Cobalt BAMF is built to perform based on that.

The lessons learned in the testing phase have been applied to the production rifle. Cobalt’s rifles are held to a standard of perfection. The receiver’s internal tolerances and surface finish are tightly controlled to a far greater degree than Mil-Spec demands. The receivers are tracked and recorded through every step of the manufacturing process; from the delivery of the bar stock to the final assembly of a complete rifle. The receivers are inspected for tolerance, function and appearance at multiple stages throughout the process. Upper to lower fit are held at between zero and two thousandths of an inch. The magazine wells are cut by the slowest, but most precise means – wire EDM. The final assembly process is taken on with the solemnity of a religious rite. One technician is tasked with hand selecting components for a rifle, based on individual fit. The receiver sets are assembled and a finger is passed over the mating edges to ensure perfect fit. The buffer tubes and receiver extensions are honed and polished inside. The buffer springs are polished as well. Safety selector barrels and takedown and pivot pins are sourced from the best firms in the industry, but are still checked with a micrometer before assembly to ensure it fits ideally in the prescribed hole, which has also been checked with a precision pin gauge just before the moment of assembly. Every screw is torqued to a prescribed load. One technician carries one rifle through the process from parts selection to test fire and ultimately packaging for shipment. His name and contact information accompany the rifle to the end user. He and he alone has built your rifle. It’s a matter of personal pride and absolute quality assurance.

The componentry selected for the BAMF rifles is all top shelf- again, from the lessons learned in destructive testing. The bolt groups are the best available; made by Toolcraft and are then treated with a high performance Nickel Boron Coating. This coating reduces the need for regular lubrication in the upper receiver. These enhanced bolt groups also add a great deal of functionality to the gun. The coating is so smooth that fouling and particulate contaminants find it difficult to adhere to the bolt group, where they might retard function. When the bolt group looks dirty and needs a cleaning, a wipe down with rag and light oil does the trick. The trigger supplied with the BAMF is from KE Arms. A unitized drop-in assembly, it is adjustable for pull weight and let-off by one screw. KE Arms’ triggers feature a titanium nitride PVD surface treatment on all the working bits. Titanium nitride is totally corrosion resistant and very hard, which results in a smooth trigger feel. The barrels are manufactured by a seasoned expert in barrel making to the standards and specifics established by Cobalt engineers. The safety selector and magazine latch and changing handle are all premium ambidextrous components. All BAMF models come standard with an adjustable gas block that features audible clicks in the adjustment valve.

Cobalt offers these rifles in two trims; the basic BAMF and the BAMF EDGE. The visible difference is the butt-stock assembly. The EDGE utilizes Cobalt’s proprietary billet stock. It’s a fixed rifle length stock that completes the aesthetic appeal of the rifle. It’s also a very comfortable and practical place to rest your cheek while shooting your BAMF. Yes, it’s heavy, but the little extra weight in the rear end of the rifle does wonders for balance and handling. The basic BAMF features a Hogue collapsible over-molded unit, attached to a Mil-Spec receiver extension tube. The two rifles utilize different barrels. The BAMF includes a 14.5-inch service weight, chrome-lined CM steel barrel permanently affixed to Cobalt’s own flash hider. The EDGE model gives buyers an option for a 16-inch chrome lined or 18-inch match-grade stainless steel barrel. All barrels are chambered in .223 Wylde. All BAMF rifles feature the signature forearm, notable by the spikes at the business end. These are indeed Picatinny bases at 12 and 6 o’clock to attach iron sights or other accessories. The forearm is also part of the statement Cobalt wishes to make about the current shape of the AR-15 that everything need not be low profile and boring to be of practical use. The forearm is also M-LOK compatible for the addition of lights, grips, bipods or additional optical equipment. Another signature feature of the BAMF forearm is the hump at the receiver end that makes room for the gas tube. Absent is the continuous “tunnel” along the inside dorsal surface of the forearm. The unique arrangement allows for the forearm to clear the gas tube where required, and at the same time, keep the forearm round, and of a smaller diameter than most free-float tubes on the market. The last standard option is the color of the rifle. The BAMF and EDGE can be ordered in 3 finishes; OD green, slate gray, and brazed (a tan/straw).

The BAMF and EDGE rifles are in production and shipping and are available at a few discerning gun dealers around the country who signed up early. These rifles may be on the backorder list from time to time, but be assured that Cobalt has no intention of keeping their wares exclusive. The company is constantly expanding and has just moved production into a larger facility, and installed more 5 axis CNC machines and another wire EDM to keep up with production demand. Upcoming additions to the BAMF lineup includes a PRO model; a rifle that has been designed taking input and direction from a few of America’s top multi-gun competitors. It has all the ideal features and capabilities required for top performance on the range. The stock and forearm have been optimized and streamlined and the trigger has been upgraded to a fully adjustable unit. The barrel is lighter and more accurate and longer wearing. The bolt group is from Cryptic and features a CVD coating that is arguably the best AR bolt group ever made. The BAMF PRO is as good as a rifle can get.

“Kinetic” in the company name at first seemed out of place as this refers to something in motion. A rifle is a solid-state machine for the most part; there is only a reciprocating bolt and occasionally a projectile headed downrange. And its motion is repetitive and cyclic. After touring Cobalt’s Utah facility, and fielding the rifles and spending time with this visionary group, we became aware that “Kinetic” refers to the company and the ideas and the people who make it run. It’s moving forward – sometimes too fast. As mentioned before, SAR was made aware of some next generation concept rifles and projects. Some of these concepts are waiting for manufacturing capability to evolve enough to make them possible. That is boldness at its best; to outrun one’s own abilities. It has been said by wise men that “fortune favors the bold.” Many a tactical shoulder patch, ball cap or challenge coin touts this theme, as a reminder to us. It would seem that this great concept has been lost on too many gun companies, who continue to make rubber stamp “M-forgeries” and are content to remain static. Cobalt Kinetics is going to cure the black rifle.

Cobalt Kinetics
1478 South 270 East, Suite #1
Saint George, UT 84790
(435) 656-0599
www.cobaltkinetics.com
www.facebook.com/cobaltkinetics27

If the television reality-show craze were to momentarily abort political correctness and expand into the gun world, there could certainly be potential in a new series called Pimp-My-Rifle. Just like the auto industry and the homebuilders have done, a bone-stock firearm could be presented for enhancement and returned to its owner in a highly modified configuration. Unfortunately, for the time being, no such reality show exists but thanks to the folks at CAA, many upgrades from mild to wild can privately be accomplished with a single phone call.

Plastic Rifle Popularity

There are several companies who specialize in manufacturing AR-15 style rifles in configurations too numerous to list here. The popularity of the semiautomatic version of America’s primary service weapon has exploded onto the civilian gun scene in the last decade evidenced by the number of major “sporting rifle” manufacturers who have added a version of the Black Rifle to their lineup. A firearm once considered on the fringe, or of limited interest, the AR-15 style rifle is no longer only being produced by specialized companies catering primarily to a military or law enforcement market. Eying a desirable and profitable market share, such well-known manufacturers as Remington, High Standard and Smith & Wesson seem to have now embraced the firearm that companies such as Colt, Bushmaster, DPMS, Olympic Arms, DoubleStar, and so many others have specialized in for decades.

With so many gun owners joining the ranks of the Black Rifle Owners Club, there has been a major influx of new ideas, points of view and weapon objectives brought forth by the fresh customer base and a desire to adapt this platform to their particular shooting discipline. This has, in turn, boosted the accessory market in volume and innovation. Jumping directly into the deep-end of the demand issue, CAA has a huge line of accessories for these rifles that continues to grow at an amazing pace. Their product line creates an environment where someone can purchase a standard, basic rifle and accessorize it for their particular purpose. Unfortunately, there have been specific cases where sensory overload occurred (too many available options and configurations) at a time when a purchase was about to be made and has led to a lost sale because the potential buyer wanted to “buy the right rifle the first time” and needed to do more research before buying.

Overload Problem Solved

One of the greatest advantages of the Black Rifle is the complete modularity built into the system. Almost any configuration in almost any caliber can be obtained with a little assistance from the aftermarket accessory industry. This means that for some shooters, especially those new to the AR-15 style rifle, the initial purchase can be as easy as a stripped-down, basic rifle, and it can be later customized to fit the specific criteria the new owner would desire. As well as making the initial purchase easier, this strategy has the potential to save the end user a substantial amount of money. Best of all, the configuration can be altered again, an unlimited number of times if desired, if a different or ever-changing end use should occur.

From Practical to Tactical… and Beyond

There is always plenty of discussion about what is considered a legitimate and useful accessory versus what constitutes an accessory deemed silly or ineffective. Ultimately this decision has to be the choice of the end user. This statement comes with a few light-hearted warnings.

• Black Rifle Bling – If you find something you can’t live without, hanging off the barrel of your Black Rifle, but it is a little “outside the box,” the ribbing from your peers is just part of the game. There are several accessories available and only you can decide what will meet your requirements. A light, a fore-grip or a laser, are usually acceptable in most shooting social circles. A bayonet lug mounted multi-blade combination lock-pick and hot dog fork might not.
• The 20-pound Light Rifle – Almost universally taunted by veteran AR-15 type rifle owners are those who purchase every accessory to the point of concealing the identity of the original firearm, and are often lightheartedly referred to as “Mall Ninjas” or “Internet Commandos.” Some guns have been intentionally over-accessorized and photographed for the web to poke a little fun at these, and some are even quite humorous. You will have to decide what you need for your new rifle based on the purpose you want it for. Just don’t mount everything you can find, anywhere it will fit, all at once.

If you are new to these rifles and maybe a little overwhelmed by the number of accessories available, consider these previous points your fair warning. They may save you some seemingly vicious but light-hearted ribbing.

The Right Touch

In order to demonstrate a series of practical upgrades to a base rifle, this writer contacted Command Arms Accessories (CAA) and explained the concept. They were asked to choose some of their popular accessories for a “makeover” on a basic rifle. In a very short period of time a few boxes arrived with several accessories and with the addition of a few components laying around the workshop, the first magazine version of Pimp-My-Rifle was underway.

The base rifle we started with had a low-end collapsible stock, a flattop upper receiver, standard front carbine-length forend, stock pistol grip and a traditional front sight & gas block.

• Stock – The makeover started at the rear and moved forward towards the muzzle. The first step was to deal with the factory stock. It was replaced with a CAA Collapsible Stock. This new stock gives the shooter a better cheek-weld and includes a no-slip rubber recoil pad as well as a small compartment that holds 4 CR123 Batteries, a short Picatinny accessory rail and an optional push-button sling swivel.
• Sling – With a mounting hole at the front of the new stock available, a one-point sling from CAA was chosen for this application. One-point slings work well in tight quarters and assist in weapon retention while incorporating quick-detach connection points.
• Pistol Grip – The stock pistol grip was replaced with a CAA Ergonomic Grip. This grip is a little wider, incorporates finger grooves and completely fills the space above the grip to the rear of the receiver for a very comfortable hold.
• Sights – Since this rifle had only a flattop receiver and standard front sight post, a combination of dot-type scope and adjustable iron sights were added and co-witnessed. They can be used in combination with each other or used individually if necessary or desired. The rear sight chosen was an LMT Tactical Adjustable Rear Sight. It is completely adjustable for windage and elevation. The red-dot scope chosen was a 30mm S.P.O.T. scope and mount from MGI Military. With several dot intensity settings this sight performs well in all light conditions.
• Rail System – Possibly the most versatile, and arguably the most popular, accessory of this rifle platform is a front rail system that allows for the attachment of numerous accessories. Since this was a project utilizing a base rifle with a standard upper receiver and front sight post, a TDI Arms X6 rail system was chosen. Manufactured from solid billet aviation aluminum, this 2-piece, 6-rail system simply replaces a standard carbine-length handguard and works in conjunction with the standard front sight. It is a drop-on rail installed with the factory delta ring and tightened with 5 bolts to secure the system. The top MIL-STD 1913 rail matches the height of the factory flat top rail to facilitate multiple accessories. Unused rail surfaces were covered with the assistance of an X6 Thermal Rail Cover Kit.
• Front Vertical Grip – The particular grip chosen for this project met a few different criteria. We used a CAA Flashlight Grip Adapter. This vertical front grip mounts on the front rail and accepts a standard 1-inch flashlight. Tactical lights with a rear button can utilize the built-in thumb switch in both a constant on and a momentary on mode. Lights with a pigtail-style pressure switch are also accommodated with built-in mounting surfaces.

Enough is Enough

Since we earlier made light of those who over-accessorize their rifles, we were cautious not to fall into that category with this build. Those who either need more accessories or just different accessories can rest well knowing that we didn’t even scratch the surface of the available items. For a full listing of CAA accessories you can visit their website at www.commandarms.com. Be prepared to be there for a while. There are numerous variants of the items we installed such as stocks, grips, mounts, slings and several other accessories not included such as magazine clamps, stock accessories, lasers and mounts, bipods and much more. They also carry accessories for many more firearms than just AR-15 style guns including AK47s, Uzis, P-90s, MP5s, Galils and several handguns.

Sources

Command Arms Accessories
76 Vincent Circle
Ivyland, PA 18974
Ph: (267) 803-1518
Fax: (267) 803-1002
www.commandarms.com

Lewis Machine Tool Company
1305 11th Street
W. Milan, IL 61264
Ph: (309) 787-7151
Fax: (309) 787-7193
www.lewismachine.net

MGI Military
102 Cottage Street
Bangor, ME 04401
Ph: (207) 945-5441
Fax: (207) 945-4010
www.mgimilitary.com

Every war is different. Every battleground has diverse characteristics. Each mission, whether a military role or civilian law enforcement detail varies greatly in its specific purposes. It seems almost impossible on the surface that a single weapon system could adapt and function in such a range of climates and missions, but the familiar M16 is still going strong. From a lightweight carbine to a heavy barreled LMG, the M16 weapon system has been fulfilling the role of America’s primary service weapon for more than 40 years and it doesn’t seem it will be replaced wholesale anytime soon.

The earliest history of the inception and design of the black rifle bas been chronicled numerous times and it is not the intent of this author to rehash this historical material other than a very brief and condensed historical summary. There are many credible sources for this information including The Complete AR-15/M16 Sourcebook by Duncan Long, The Black Rifle I by Blake Stevens, Black Rifle II by Christopher R. Bartocci and an extensive Colt M16 ID Guide in the Machine Gun Dealers Bible by Dan Shea. This article will focus on the versatility of the M16, the characteristics that have allowed the metamorphosis from the original designs to the current battle rifle of the 21st century and possibly beyond.

Although there are a countless number of model designations for these rifles from numerous manufacturers, for simplicity purposes in this article, the designation “M16” can be assumed to be a fully automatic rifle while the designation “AR-15” makes reference to the semiautomatic version.

A Very Brief History

While its initial roots are clearly in the Stoner designs of the early 1950s, like most designs, the multiple lug bolt head, lockup into a barrel extension, and gas system principle can be traced back farther. It was at ArmaLite where this all came together. The first heavy public exposure to the black rifle started in the wet and humid environment of the tropics with the earliest variations sent to US troops in Viet Nam. There were many positive responses at first, but after the ammunition/propellant change, the black rifles were plagued with an extremely lackluster initial impression and poor performance in the field. Problems were eventually minimized after several rounds of intense testing combined with numerous committee change recommendations. Many alterations in production were initiated including chamber dimensions, rifling twist ratios, firing-pin changes, redesigning the flash hider and charging handle, and (against the advice of many people) the addition of a forward assist assembly. Along with ammo and gunpowder refinement, proper maintenance, and problems addressed with early magazines, the early version of black rifle as we know it today was on its way to becoming the cornerstone of the modern American military arsenal.

As early as 1963, Colt started manufacturing this “new” rifle in semiautomatic only with the civilian population and the law enforcement community in mind. Sold as the AR-15 Sporter it was virtually identical to the M16 with the exception of the fire control group. With an early retail price of $189.50 it was marketed to the hunting and sporting community as a beacon of a new wave of manufacturing technology allowing it to be lightweight while remaining accurate and effective. Although several minor changes have been made to separate the function of the semiautomatic version of these rifles from their fully automatic relatives over the years, and to keep them from being easily converted to fully automatic, they remain wildly popular and an enormous civilian market thrives today. Numerous upgrades and model enhancements of the civilian line of semiautomatic variants have followed very closely to those designed for the fully automatic models keeping them on a fairly level playing field.

With the 1977 expiration of Gene Stoner’s patent on the M16 gas system, several companies sprang up and started manufacturing their own versions of this popular rifle. The trademark model name of “AR-15” was, and still is, owned by Colt, and they are still one of many businesses that manufacture this weapon system and its many configurations.

Modularity is King

At the heart of the black rifle is the versatile lower receiver. This portion of the firearm is the section considered by federal law to be “the firearm” by definition. The lower receiver is the portion of the firearm that contains the trigger group and the pistol grip as well as the magazine well. Also attached to the lower receiver is the buffer tube and stock. This is the part that requires purchase through a licensed federal firearms licensee (if ordered from an out-of-state dealer) and the paperwork that goes along with any other firearm purchase, depending upon the laws of the State of the buyer. Every other part of this firearm may be ordered directly by the end user and requires no federal licensing or paperwork. All other parts, including the upper receivers and the barrels are treated just like any other non-regulated parts.

The upper receiver plays an equally important role in the mechanism. The upper receiver is the point of attachment for the barrel and the housing for the bolt, bolt carrier and charging handle. It is attached to the lower receiver by two takedown pins that are operable without the aid of any tools. The upper and lower receivers may be separated and rejoined at any time without fear of losing any components under normal handling. This may be attractive for size considerations when breaking down for transportation or when changing the characteristics of the rifle for a specific task.

Several rifle configurations may be assembled on a single lower receiver simply by swapping out barreled upper receivers. Specific tasks may require features unique to that task but may not be desirable to others. This is where the real beauty of the black rifle comes in. Unlike most other firearms, the characteristics of the black rifle can be altered at any time, and reversed back again, just by changing upper receivers. It is indeed more than a weapon; it is truly a “weapon system” as it is often properly referred as.

For obvious reasons, an entry-type rifle may consist of a very short barrel and either iron sights or a zero-magnification dot-type sight. A varmint hunting rifle may be much more effective with a long barrel and high power telescopic sight. With a black rifle, both of these configurations are only a quick upper receiver swap away with no lack of performance in either field.

There are barrels ranging from the 7-inch* “Kitty Kat” barrel from DPMS (www.dpmsinc.com) to a 24-inch Varminter Extra Heavy Barrel from Bushmaster Firearms (www.bushmaster.com) and a multitude of lengths in between. (* Under Federal Law a rifle barrel has to be over 16 inches in length to be a legal Title I firearm. By purchasing or registering the rifle as a Short Barreled Rifle, the owner can use any barrel length at will. With registered machine guns, the barrel length is not a legal stipulation under Federal Law and any length barrel may be used). There are not many rifles that allow the flexibility of swapping out barrel lengths without the necessity of tools in less than 30 seconds like this system. Additionally, another major advantage is the sights are part of the upper receiver as well, so there is no need to re-zero after making this swap. If multiple barreled upper receivers are owned, they can all be sighted-in and swapped as desired with a complete return to zero with careful handling and the correct ammunition.

From Plinking to Protecting

If there is any one thing that can always be counted on in the firearms community, it is American Ingenuity and the desire to make something bigger and better. (Sometimes smaller and better, in this case.) Fortunately, this has proven to work well in transforming the once light .223 Rem. (5.56x45mm) rifle into something left only to one’s imagination and budget. With the ease of changing upper receivers, the transformation from the original caliber to a completely new round is almost as simple. Since the upper receiver holds the barrel, bolt and bolt carrier, this is the portion of the rifle where the caliber of the ammunition to be utilized is determined. Thanks to many able minded firearm enthusiasts, these rifles can be converted to almost any caliber ranging from .17 to .50 BMG with minimal (if any) temporary modifications to the lower receiver. From the luxury of plinking for recreation on a budget or additional training, to having the stopping power to assist our front line fighters in the War on Terror, the black rifle can be custom configured to suit every application.

One of the most popular subcaliber units among black rifle shooters is the “Atchisson” .22LR conversion manufactured by Jonathan Arthur Ciener, Inc. (www.22lrconversions.com). When utilized with the recommended ammunition, properly maintained and operated, they provide hours of plinking fun in semiautomatic AR-15s or full automatic fun when used in conjunction with a registered M16. On the opposite end of the ammunition spectrum is the .50BMG Upper Receiver from Watson’s Weapons Inc. (www.watsonsweapons.com). This upper receiver actually allows the use of the massive .50 BMG round when attached to your lower receiver. It functions as a single-shot rifle that must be partially taken down to be reloaded between shots.

One of the most popular pistol caliber conversions would include the 9x19mm (Luger) conversion. First introduced in 1985, Colt offered a 9mm blowback-operated submachine gun that worked quite well. Most of the characteristics were the same as the standard rifle, making operation simple for anyone who had utilized or trained on the 5.56x45mm rifle. A special magazine (both 20-round and 32-round) was developed for the much shorter 9x19mm round and a block was pinned inside the standard lower receiver’s magazine well to accommodate the smaller magazine while utilizing the same magazine release. A civilian version was soon to follow in semiautomatic only with a 16-inch barrel. Other than the upper receiver and bolt differences, only the buffer was changed to a heavier one, and a few of the trigger group parts were slightly modified. In the 1990s, the US Drug Enforcement Agency adopted a silenced version of this rifle. The Department of Energy also adopted a very short variation known as the Model 633, commonly called a “DoE Upper.” The 633 had a 7-inch barrel, collapsible stock and a front handguard to keep the operators hands from straying in front of the muzzle.

Several other companies started manufacturing these pistol caliber conversions with numerous types of feeding systems. While a few emulated the Colt style mag-well block and use the factory Colt 9mm magazines, others used highly modified magazines reworked to fit the interior portion of the factory magazine well. Although many of the modified magazines work very well, they are often expensive and the availability is less than desirable in most cases. Even though there are several manufacturers of aftermarket (any non-Colt) black rifles including several Caliber conversions, the pistol caliber most often encountered remains the 9x19mm.

Many different calibers in black rifle variations have been written about here in the pages of Small Arms Review over the last 10 years. While there are new caliber combinations coming out at an amazing rate, some of the latest ones we are familiar with include the Alexander Arms .50 Beowulf and 6.5 Grendel, (www.alexanderarms.com), .502 Thunder Sabre by Cloud Mountain Armory (www.bigborecanyon.net) and lastly the .45 Bushmaster (www.bushmaster.com). We will be testing the .45 Bushmaster for a future issue of Small Arms Review very soon. Some of the more common calibers include, but are not limited to: .308 NATO*, 7.62x39mm and 6.8SPC and can be found from multiple vendors. (*.308 NATO (7.62×51) requires a different lower receiver due to the longer interior dimension of the magazine well necessary to accommodate that particular round).

Feed Me, Seymour!

Like the hungry man-eating plant named Seymour in the 1960s cult classic film Little Shop of Horrors, a black rifle is always hungry and never seems to be fed enough. Firearms, especially those in a military role, are no exception. The earliest magazine design of the AR-15 was a 25-round magazine, which had problems due to being straight, and was immediately replaced with a 20-round magazine. The first ones were steel “waffle” pattern magazines, which were also immediately replaced with the standard aluminum 20-round magazine that eventually evolved into the 20-rounder so common today. In the mid 1960s, a 30-round magazine was manufactured with a slight curve and it seemed to work great in all new rifles but had a hard time feeding in some, including the earlier ones. This was corrected in part by keeping the top portion of the magazine straight like the 20-round version and starting the curvature at the bottom of the magazine well. These magazines still had a reputation for jamming if they were loaded to 30 rounds, and the SOP was load to 28 rounds. This was corrected later by stabilizing the follower with equal leg lengths.

In order to address this “need for feed,” Colt experimented with a belt-feed mechanism that operated with a modified upper and lower. With a 20-inch barrel this unit weighed in at almost 8 1/2 pounds without the bipod or ammo box. The belt fed M16 never made it to production.

Fast forward to the early 1980s and bring Jonathan Arthur Ciener back into the picture. A manufacturer primarily specializing in sound suppressors at the time, Jonathan took it upon himself to redesign and reintroduce the concept of a belt-fed AR-15 and M16 and made them available to the general public. When they were evaluated for the now defunct Machine Gun News in 1992, this writer had the pleasure of working on the article and spending some trigger time with these guns. We were provided with both a semiautomatic model and a fully automatic model. They were built on factory Colt AR-15 and M16 rifles, and like Colts early design the upper and lower receivers were both modified. The Ciener system had a few very interesting points. First, the belt-feed mechanism could be removed from the weapon and it would again accept factory magazines. Second, Ciener produced some of the belt boxes which locked into the magazine well, as in the original design.

We tested them under several conditions with many types of ammunition in semiautomatic and full automatic. We tested it in belt-feed and magazine feed. We tested it with and without the addition of a sound suppressor. In summary it performed excellently. The only drawback was that in the case of a jam it was a “4-handed” operation to clear it and have it up and running quickly, but with a little practice it could be done quite efficiently. It also used a proprietary, modified link that was quite expensive at the time compared to standard unmodified links. These were sold for a few years but were eventually discontinued due to the enormous amount of time necessary to manufacture them.

There are a few current belt-feed systems for the black rifle but nothing yet has reached a mass marketing level. In the March 2003 issue of Small Arms Review (Vol. 6, No. 6), the Shrike 5.56 from Ares Defense (www.aresdefense.com) was covered in great detail as it was due to be released en masse around the time of publication. To this date, it is still being manufactured, released and shipped in very small quantities due to several redesign upgrades and improvements. The great attraction to the Shrike 5.56 is the fact that it works in conjunction with a completely unmodified lower receiver. All attempts at a belt-fed black rifle in the past have required major lower receiver modifications. Like the Ciener, model it can be fired from belt or box magazine but in the case of the Shrike 5.56, when the belt is out, a box magazine is simply inserted, the rifle charged and firing is uninterrupted. There are no parts to take out or change over. We are anxiously awaiting mass shipments of the Shrike 5.56 and will certainly test the newest production model as soon as they are shipped.

Another interesting belt feed option for the black rifle is the XMG from BRP Guns (www.brpguns.com). The XMG34 is essentially an MG34 “upper receiver” designed for use on an M16 lower receiver. Currently in its 5th year of production this inexpensive alternative to an original MG34 has been receiving great reviews for years. Available in 8mm and in .308, they are popping up at ranges nationwide and are becoming more popular with every passing year. They will function in fully automatic when used in conjunction with a registered lower receiver and require only a small (nonpermanent) modification to function.

Seeing a need for a belt-fed black rifle that is inexpensive to feed, the master of the miniatures, Lakeside Machine of Tippmann Arms fame decided to design a .22LR belt fed upper receiver with a similar mechanism to the popular Tippmann 1/2 scale miniature machine guns. (www.lakesideguns.com). This upper receiver, available for both semiautomatic and fully automatic function, was tested in the April 2006 (Vol. 9, No. 7) issue of Small Arms Review. The only modifications required to the lower receiver in this assembly are the exchange of the factory buffer and the suggested replacement of the hammer spring.

Understanding the demand for more ammo capacity than the 30-round magazines were able to provide, the Beta Company, of Atlanta, Georgia (www.betaco.com) worked with Jim Sullivan of the old ArmaLite and the M16 design fame, the original inventor of the 100-round C-Mag. Sullivan worked as a consultant with Beta Company in the early developmental stages of the new Beta C-Mag and with the introduction and advances in plastic materials and its ability to keep tight tolerances the C-MAG as we know it today has developed into an extremely reliable system, all while keeping weight to a minimum.

Mounting Madness

We live in a market driven economy and combined with the simple truth that necessity is the mother of invention, some “solutions” have been presented to us for “problems” we may never have known existed otherwise. In the last several years there have been an enormous number of accessories manufactured for mounting on MIL-STD-1913 rails. Along with these accessories came a mad rush for mounting platforms, and the standard factory handguards on the AR-15 and M16 are quickly being antiquated and replaced with new and improved rail systems. There are several to choose from including the Knight Rail Interface System (RIS) and Rail Adapter System (RAS) (www.knightarmco.com), VLTOR VIS System (www.vltor.com), POF-USA Predator Rail System (www.pof-usa.com), LMT Monolithic Rail Platform (www.lewismachine.net) and many more. All of the aforementioned have been of excellent quality.

For those not needing the precision, or wishing to spend the amount of money those mentioned may cost, some simple handguard replacements have been introduced that incorporate rails into them and some rail adaptors have been manufactured that simply bolt on to the existing A2-type handguards. A few of those have been utilized for testing devices like vertical grips where a slight amount of movement was not detrimental to the system and they performed fine. Other applications like mounting optics or more “load bearing” accessories would probably not be recommended for the latter systems.

All the new configurations and types of intended deployments these systems are capable of bring the necessity of new support equipment. One area where a serious advancement has been made is in the sighting systems available. Electronic “dot type” sights are very popular for close-up work and there are many types and styles. A few extremely popular systems include the EOTech Holographic Sight (www.eotechinc.com), the Aimpoint CompM4 (www.aimpoint.com) and the Trijicon ACOG (www.trijicon.com). While each system has distinct advantages the author is very familiar with the EOTech model 552. It has several settings for use with a night vision monocular as well as the standard day settings. The Holographic Sight is placed in a forward position on the top rail and utilized as usual during normal daylight. During low light the monocular is mounted behind it so the operator can use it at night without having to re-zero the weapon.

Along with the popularity of low or zero magnification electronic sights, the demand for a well-made, high quality, Back Up Iron Sight (BUIS) has been high for use during a potential electronic failure. Several contenders on the market include the Troy Industries, Inc. Folding Battle Sight (www.troyind.com), the GG&G Flip-Up Sights (www.gggaz.com), and A.R.M.S. Inc., #40 Folding Sights (www.armsmounts.com). An interesting front sight is the POF-USA FTA2005 Front Sight. It is not a folding sight but a stationary sight that is hooded for an extremely fast target acquisition and has been found to be complementary to use in conjunction with “dot-type” sights or as a stand alone with the correct rear BUIS. Due to the great number of new sight requirements, many of the modern rifles are available with a removable carry handle. Once the familiar carry handle and rear sight is removed, a standard MIL-STD-1913 rail is exposed to be used alone or in conjunction with these new sights and rail systems.

Another interesting new front sight was recently introduced for the black rifle. It is made by KNS Precision (www.knsprecisioninc.com) and is actually a circular “peep” with a crosshair in it. Initial testing appears it is fast and accurate and we are anxious to spend more time with this new front sight as well as several more of their latest offerings.

As a Catch-22, these new mounting platforms that were spawned from new items in need of mounts have spun off their own items made to be mounted on this newly available space. There are several devices available for mounting on MIL-STD-1913 rails including visible lasers, IR lasers, and lights. optics, night vision, camera equipment and many more items. Some earlier available items that were designed to mount on standard handguards or directly on the barrel have even been redesigned to mount directly on a rail system due to the high proliferation on later models. A prime example is the new rail mount 40mm LMT M203 Grenade Launcher. This tried and true M16 accessory used to mount on the barrel of the standard black rifle and a special handguard replaced the factory A1 or A2 handguard issued with the rifle. With the new rail mounted version, no additional handguards are necessary and due to the nature of the mounting system there is no longer any stress on the barrel as it is allowed to free-float with many current rail systems.

AR Accessories

As mentioned previously, several companies exist today just to service this weapon system. A quick glance around the Internet or any large, stocking gun shop will uncover thousands of items geared toward users of the AR-15 and M16 weapon systems. A look at KNS Precision and their product line will unveil several components for the black rifle useful in simple preservation roles such as pins that are designed not to rotate and egg-hole the aluminum receivers at the thin section supporting the hammer and trigger pins. They carry a variety of sights for target, plinking, competition and tactical applications and even manufacture a set of Spade Grips so you can shoot the rifle in the same manor as a 1919A4 with butterfly grips or an M60D model. We tested these grips in the May 2007 (Vol. 10, No. 8) issue of Small Arms Review and we found them a blast to shoot, especially with a pintle mount and Beta C-MAG. They are well made and functioned flawlessly.

While you are in research mode, take a peek at some of the products in the Command Arms Accessories line (www.commandarms.com). Some of these accessories manufactured for the AR-15 and M16 weapon system look more like they came back from a fact finding mission from the 22nd Century than from Ivyland, Pennsylvania where they are located. With accessories and upgrades from buttstock to muzzle, the only part of the original weapon system that looks familiar is the distinct shape of the receiver section. Watch for a piece in an upcoming issue of Small Arms Review where we take a “Plain Jane” AR-15 and give it the complete CAA treatment while testing it every step of the way. We are looking for something that really enhances performance and not just cosmetics and we have been assured we will not be disappointed.

Back to the Future

There is one unique feature of the black rifle that is as controversial as all other designs combined. This would be the way the gas system of the firearm operates and whether changing it is considered an upgrade or downgrade by the user. The black rifle operates with a direct impingement gas system in the following manner. When the rifle is fired, the rotating bolt is in its locked position in the barrel extension. As the bullet passes a gas port located under the front sight, some gas is bled off into a gas port and directed through a gas tube to the rear. The hot gas pressurizes the gas tube and the rear end of the pressurized tube is the gas key located on top of the bolt carrier with the gas thus exerting rearward pressure on this movable part. This pressure starts the bolt carrier traveling rearward, unlocking the bolt via its cam pin in the cam path on the carrier, and initiating the extraction. The bolt carrier travels rearward, and the projectile exits the bore evacuating the pressurized gas from the gas tube, ending any rearward pressure from the gas system. That time under pressure is critical to reliability and is dictated by the amount of time the bullet is traveling in front of the gas port. As the bolt carrier passes into the buffer tube (concealed in the stock) the fired casing is ejected. Met with a forward amount of spring tension from the now compressed buffer spring, the bolt carrier is returned to the front, picking up a new round from the magazine, loading it in the chamber and rotating and locking the bolt to restart the sequence.

The problems with this particular system are multiple. It is dumping combustion byproduct – “dirt” – into the same place it feeds ammunition from. This leaves a lot of carbon buildup over time and can create function problems when not maintained regularly. The lower receiver and its trigger group are often heavily soiled from this gas system and it is compounded numerous times over when combined with the use of a sound suppressor. Due to the carbon, unburned powder and extra heat following the path of least resistance, the extra back pressure created with the use of a silencer leaves more debris than normal and blowback is often an unpleasant effect inflicted on the shooter. On top of the maintenance issue, which in the recreational shooting world should be a no-brainer, is an issue not often spoken about. As indicated before, the additional debris is carried back into the action of the gun and it is carried by very hot gas. It has been suggested by some people that the effect of these hot gasses under heavier than normal shooting conditions could cause metal temperament problems over time. A heavy influx of heating and cooling could create some structural problems with extremely heavy use.

There are several systems that now use a gas piston system in place of the direct impingement system and Small Arms Review has covered several of them in the past. In the last two years we have examined the HK416 System, the POF P-416 System and just recently, the Colt LE1020 Advanced Law Enforcement Carbine. Fairly recently, Ares Defense introduced their GSR-35 Black Lightning system, which is a drop-in piston kit that takes the place of the original gas tube and bolt carrier. Leitner-Wise Rifle Company (www.lwrifles.com) also specializes in a piston system however we have not had the opportunity to evaluate it yet. While the concept is certainly nothing new, (Colt experimented with a piston system in the 1960s, and there are many other examples pre-dating that) its time certainly seems to have come and it appears to be here to stay.

Other than a brief amount of time spent working with an early “Rhino System” in the early 1990s, of all the systems mentioned above, this writer only has an extensive amount of time on the POF P-416 system at this point. Other SAR contributors have extensive trigger time on the HK416, and will cover other systems in the future. On the POF system that I have tested, there are definite advantages that have been witnessed, primarily the number of rounds it is able to run with little or no maintenance with no malfunctions. The POF P-416 utilizes C.R.O.S. (Corrosion Resistant Operating System) where their major components are impregnated with silicon nickel creating an incredibly slick surface. After firing several thousand rounds, the surface easily wipes clean with only a dry cloth, and after almost 20,000 rounds in one particular test unit there is no visible wear on any of the coated parts.

During initial testing the system was fired in excess of 9,000 rounds with no maintenance or lubrication of any kind and when it was finally cleaned because we thought there was a single failure to feed, ending the endurance test, it was later found that it was a faulty magazine creating the feeding problem and not the gun itself. Another factor that assists the P-416 system in functioning so well under harsh treatment is the fact that there are no gas rings necessary since there is no actual gas pushed back into the bolt carrier. This seems to translate into a firearm that will operate in a harsher environment due to much lighter tolerances. Without the presence of gas rings creating a seal between the bolt and bolt carrier, everything moves much smoother and is less meticulous in its typically tight tolerances.

If there is an immediately noticeable advantage in this particular gas piston system it is durability. On top of the several thousand rounds fired with no maintenance except for the initial cleaning after the perceived stoppage, many of them have been in a succession so rapid that it would have been certain failure for a direct impingement system; melting the gas tube and ending the testing very early on. After years of testing black rifles, the author has a collection of failed gas tubes, many resembling spaghetti found lying on top of the barrel after reaching the point of failure. If there are any immediate disadvantages of this gas piston system over a direct impingement system, this author has not yet noticed them.

Now Left Can Be Right

A fantastic example of how the civilian market often takes its own direction and even has the potential to influence the military marketplace is a manufacturer from New Britain Connecticut named Stag Arms, LLC. (www.stagarms.com). Founded in May of 2003, Stag decided to cater to a percentage of the market who had been all but ignored for years. They completely redesigned the upper receiver, bolt and bolt carrier to eject from the left, specifically for left-handed shooters. Featured in the March 2006 (Vol. 9, No. 6) issue of Small Arms Review, southpaws will never again have to depend on a brass deflector keeping hot brass from hitting them or crossing their line of fire.

The Future

It is the versatility of the AR-15/M16 that has allowed it to adapt and thrive in so many differing environments and it is the modularity of the system that is a direct contributor to its survival and evolution. There are a few companies that are addressing this in ways that could never have been originally conceived 40 years ago and will lead the way into a long future for the black rifle.

MGI (www.mgimilitary.com) has been in the black rifle business for decades. Their upgrades have been chronicled in the pages of Small Arms Review several times including their Rate Reducing Buffer – May 2004 (Vol. 7, No. 8), The QCB Upper Receiver – December 2004 (Vol. 8, No. 3) and most recently The Hydra Modular Weapon System – May 2007 (Vol. 10, No. 8). With such versatility as a quick-change barrel upper receiver that requires no tools and works with original factory barrels, changes in length, style and caliber have never been faster, easier or less expensive. The Marck-15 Lower Receiver with interchangeable magazine wells, again with no tools, allows the correct magazine to be used to coincide with the caliber being fired. For example, if you are utilizing a 7.62×37 barrel and bolt, you can use the AK mag-well and utilize standard AK47 magazines. This ensures the correct feed and presentation rather than redesigning a new magazine around an existing space and angle. Mags are inexpensive, available and reliable. Next in the works is a 9mm SMG mag-well that will utilize the factory Colt 9mm SMG magazines. Several new offerings are in the pipeline, some certain to be out even before this magazine hits the newsstand.

Cobb Manufacturing (www.cobb50.com) has a line of rifles called the MCR (Multi Caliber Rifle) and it is based on the design characteristics of the AR-15, just a little bigger. The MCR is a semiautomatic, gas operated system that can be chambered in a long list of calibers from 9mm to 338 Lapua, designed originally for the SCAR rifle program. They are far from newcomers to the industry and have been dealing with such innovative firearms as the .50 BMG FA50 and BA50 for several years. Teamed up with top-line suppressor manufacturers their systems are well made and versatile.

With the “feeding” frenzy a constant issue as discussed previously, we expect to see upgrades and alterations to this portion of the weapon system as long as it is in use. Just before finishing this article the author received what is perhaps the latest offering to the high-capacity quest to evaluate for a future article. It is the CL-Mag from Armatac Industries, Inc. (www.armatac.com). Resembling the Beta C-MAG in shape, the CL-Mag is manufactured from aircraft aluminum and holds 150 rounds of 5.56x45mm. Finished in a hard coat type III anodized finish, it is intended to work in all AR-15/M16 variants. We are anxious to proceed with testing this new feeding system in the near future.

Conclusion

Since there is really nothing to compare the popularity of this unique weapon system to, with its longevity in both military and civilian applications, it is the opinion of this writer that the sheer ability to act as a chameleon and adapt to almost every environment is the life force behind its ever growing popularity. It has to be noted that many of the upgrades and enhancements are civilian based ideas with no military spec sheet giving them direction. Some of these ideas and items can be looked at as simply “fun” and that is an important aspect of shooting that some of us who are a little too hung up on being “professionals” tend to overlook a little too often. Not everything that is discovered or tested has to have an adrenaline soaked special operations application in mind. Some of the best gear for our professional applications stands a chance of starting out as a light-hearted civilian product, just because it is looked at and designed with fresh, new, untainted eyes. Some of the greatest design innovations this writer has witnessed have come from challenges from people who specifically stated that in their professional opinion something couldn’t be done.

With an ever-changing requirement for the ultimate weapon system in this unpredictable War on Terror, if any weapon stands the test of time it is the AR-15/M16. With a virtual flood of new accessories, upgrades, calibers, finishes, furniture and design enhancements being introduced at breakneck speed, this writer has a hard time even thinking of the day where the black rifle or some form of it is not going to be the basis for our primary service weapon for at least 40 more years.

Author’s Note: While this article started out to be a short overview of the AR-15/M16 and its longevity, it soon became obvious that it could not be done in just a few words. The system is too complex and the changes, alterations and upgrades are far too numerous to simply skim over and condense. Unfortunately, due to space constraints, it had to end somewhere and we were not able to include every single company that offers firearms and accessories related to this weapon system. They are far too numerous, and even a quick glance through the pages of Small Arms Review will reveal several more businesses who specialize in parts and accessories for the black rifle. It is not our intention to promote anyone in particular while leaving anyone else out, nor should either be misconstrued as an endorsement or lack of such in the latter case. We would be happy to put together a condensed Black Rifle Buyers Guide listing every business related to this system in the future, but had no room to so in this article.

For more than 40 years now, M16 series firearms have been the American military’s weapon of choice. It is fair to say that few small arms have created such a history of controversy, which still persists to this day. What actually happened early in the Vietnam War forms the basis of ongoing misinformation and misconceptions about the M16 & M16A1 rifles. These weapons unfairly “earned” a reputation for malfunctioning when they were “dirty” and for being a lightweight piece of junk to many. The truth, however, is much more complex than the standard line that the gun did not work due to fouling. The M16’s initial reliability issues should not have fallen on the Black Rifle itself, but on the U.S. Army Ordnance Corps which was ultimately responsible for developing and fielding weapons used by U.S. soldiers.

The new lightweight rifle was adopted in 1964 based on its “superior performance” over the heavier M14 with its 7.62x51mm NATO cartridge designed for longer range engagements. The M16 was seen by many, including Special Forces advisors, as a good infantry weapon “nearly perfect” for combat conditions in Vietnam. With a larger “basic load of ammunition,” these small caliber, lightweight, low recoil weapons proved ideal for rapid multiple target engagements and close quarter fighting often encountered in Southeast Asia. Without digging into the early history of the U.S Air Force AR-15’s & M16’s, we will look at what went wrong “in the jungles of Vietnam.”

Soon after the new black rifles were deployed into ground combat with front line Army and Marine units, reports of significant malfunctions began to circulate across Vietnam and back to the States. Many of these problems stemmed from U.S. Ordnance Corps’ defiance, prejudices and outright negligence, which proved serious enough by 1967 to warrant a Special Subcommittee on the M16 Rifle Program in the U.S. House of Representatives. These proceedings within the Armed Services Committee are now known as the Ichord Hearings, after the chairman, Rep. Richard Ichord. The details of the entire M16 program brought out during these hearings showed incredible mismanagement and gross negligence which directly caused weapons to malfunction in the jungles of Southeast Asia. After the real problems were brought to the surface, corrective action was finally taken to develop a weapon system that would function properly with its ammunition and could be deployed reliably in extended combat operations for decades to follow. We will now take a hard look at the errors, oversights, and solutions which lead to the combat proven M16A1.

Fateful Selection of Ball Powder

Most problems encountered with the rifle would be based on the Ordnance Corps’ decision to load 5.56mm ammunition with Ball powder instead of the IMR powder it was designed for. The decision was made carelessly and without testing to see if the Ball powder would have any adverse effects on the rifle. This was a grave error, one that the government would be warned about both by Gene Stoner and by Colt’s.

So what difference does the powder make? All the difference in the world. Auto loading firearms are by far one of the most complex of all machines. The tolerances and manufacturing processes are very unforgiving. A military rifle is a weapon system. That system is made up of a weapon, cartridge, propellant, primer and bullet. Any time one is changed, it must be tested and qualified before a change is implemented to insure the integrity of the weapon is not compromised. It was not.

Ball powder caused a series of malfunctions due to its different burning properties from the IMR powder the rifle was designed around. Keep in mind that the gun and ammunition were designed together. Ball powder has a much sharper pressure curve (burns faster) and increased the port pressure of the rifle. This increases the cyclic rate of the firearm by more than 200 rounds per minute. What this means is the timing of cycling of the firearm was dramatically sped up. The rifle was designed to fire at a rate of 700 to 800 rounds per minute, with ball powder it was increased to nearly 1,000 rounds per minute. This alteration of operation caused numerous problems including exceeding the cyclic rate maximum. It was so bad that Colt (by instruction of the Army) performed acceptance testing with older lots of cartridges loaded with IMR powder so that they would meet the lower cyclic rate as specified in the contract with the Army so the rifles could be delivered to the Army. Ball powder has been used going back to World War II. Large stocks remained from that time period that could be converted into rifle powder. This significantly decreased the cost in comparison to IMR powder. The main problem with IMR propellant was the inability for DuPont to manufacture the quantities needed to the specifications required. The actual decision to use ball propellant for this rifle system was not a bad decision, the problem came into how they implemented it. The rifle/ammunition were not tested and qualified before ammunition with Ball propellant made its way to the jungles of Southeast Asia.

Failure to Chrome Plate the Chamber

The principal and most serious cause of the malfunctions of the AR-15/M16 rifle in Vietnam was the failure to chrome plate the chamber. From experience gained in the Pacific Theater during World War II, it was found that chrome plating a chamber of a firearm would prevent many serious failures to extract. This military requirement was set forth by Ordnance Technical committee since 1957. Corrosion causes pitting in the chamber. When the cartridge is fired, it expands to the walls of the chamber. The cartridge would stick in these pits causing the extractor to tear the rim off the cartridge cases and the only way to remove it was to hammer it out with a cleaning rod. If the chamber was corroded and pitted, no cleaning would make it function properly. The question is, if we learned this lesson in World War II and made it a military specification on all U.S. small arms, why did the AR-15/M16 rifle not have it? The blame here goes not to Ordnance Corp but to the “Wiz Kids” on Secretary of Defence McNamara’s staff who made all the decisions. This micromanagement of money in resources and decisions was made by people who had not the slightest clue about small arms. As stated by William Davis, Jr. about the decision to not chrome plate the chamber, “If the rifle needed a chrome chamber Stoner would have designed it that way. So it did not have one therefore it did not need one.” Despite that fact, the rifle that Stoner and Colt showed the government was not a finalized weapon. It would need development to get ready for the troops to use at large.

This problem was simply corrected. First to appear were barrels with chrome plated chambers only. The barrels were marked “CMPC”(Colt magnetic particle inspected and proof tested). Barrels were also sent to Rock Island to have the chambers modified and chrome plated. This prevented the serious failures to extract and made the chamber easier to clean. Later in the war, the barrels were chrome plated in both the bore and chamber. These barrels were marked “CMPB” or “ CMP Chrome Bore.” With this modification the failures to extract became a thing of the past in the rifle.

Additionally the original gas tube was made from AISI 4130 steel. Due to corrosion issues that came up in the jungles of Vietnam the gas tube material was changed to stainless steel. This was implemented in the 1966 to 1967 time frame. This change eliminated the corrosion issues.

Failure to Extract

Failure to extract problems were due to the bolt unlocking sooner due to the change-over from IMR to Ball powder. There was still high residual pressure in the chamber and the cartridge cases did not have sufficient time to contract to be easily removed from the chamber. Thus, the extractor would slip off the rim or shear part of the rim off leaving the fired cartridge case in the chamber. To clear this malfunction, often the bolt would be closed again and the cartridge would come out of the chamber. If you compounded this malfunction with a corroded and pitted chamber, the cartridge case would become lodged in the chamber and have to be pounded out with a cleaning rod. This was by far the most serious of any malfunctions of the M16 in Vietnam. Chrome plating the chamber cured the extraction ill. The next major improvement to extraction took place in the 1970s with the addition of the rubber extractor spring buffer, which greatly increased extractor force. This particularly helped carbines that had a much higher cyclic rate.

Fouling

Fouling has been played up by many as the main cause of the failures in Vietnam. Many claimed that the gun would malfunction and the only way to get it working again was to tear it down and clean it on the battlefield. This was not the case. The main malfunctions were caused by corroded chambers causing failures to extract. No matter how clean the rifle was, it would not function reliably with a corroded chamber. Cleaning will not increase bolt and fire control group strength to prevent parts breakage due to the significant increase in cyclic rate. However, Ball powder did cause more fouling in the firearm, particularly in the chamber and inside the bolt carrier in between the back of the bolt carrier and the rear of the bolt. Simple maintenance took care of this, but maintenance became a problem of its own. It should be noted that to this very day the military M855 Ball cartridge uses Ball powder and the M16A2 and later generation rifles work very well.

Correcting Slam Fire Issue

One of the earliest problems to surface was slam fire. Slam fire occurs when the bolt is released and the firing pin strikes the primer and that inertia is enough to set the cartridge off. The principal culprit was the inconsistency in the manufacturing of the primers. When soft batches of primers were loaded this was more evident. To cope with this problem, the weight of the firing pin was decreased thus correcting the problem. There was a complete retrofit of all the old firing pins with the new ones service wide. Based on my research, the old firing pins were destroyed to keep them from surfacing at a later date and causing slam fire problems.

The “Light Strike” Problem and Newly Designed Buffer to Cope

The “light strike” was consequence of the higher cyclic rate. This malfunction was only found on fully automatic fire. When the cartridge is fired, the bolt carrier moves to the rear and the hammer is held by the automatic sear. The bolt carrier moves forward by action of the buffer spring, strips a cartridge off the magazine, chambers it, and as the bolt moves into the locked position, the sear trip area on the back of the bolt carrier tips the auto sear releasing the hammer to fire. But when the bolt carrier slammed into the barrel extension, it would momentarily bounce off the barrel extension and when the hammer would strike the bolt carrier, it would not be completely closed. The hammer would ride the firing pin/bolt carrier group forward and by the time it would lock there would be insufficient energy left to fire the cartridge. Thus, there would be a light dent on the primer but the round would not fire.

This problem would be corrected by the redesign of the buffer/spring guide. The original buffer, which utilized the “Edgewater ring springs,” was basically a spring guide that worked well with IMR propellant. For use with ball powder, five sliding steel weights were inserted inside the buffer and in- between them are small rubber disks. The weights would be able to move freely inside the buffer. This accomplished a couple things. First, it slightly decreased the cyclic rate on the closing stroke. Secondly, it prevented the bolt carrier bounce. As the buffer moved rearward when fired, inertia kept all the weights to the rear and when the bolt carrier would move into the locked position the weights would move forward absorbing the energy preventing the bolt carrier bounce.

Excessive Parts Wear and Breakages

The bolt itself would crack and break from the higher velocity and impact caused by the higher cyclic rate. The rear of the disconnector would break as well. These components worked properly at their design parameters but the increase in cyclic rate caused them to be overworked and eventually fail. The bolt catch was found to break with extended use due to the higher cyclic rate. It certainly was not that the rifle would not work with ball powder, it would have to be modified to do so. That was the job of the Ordnance Corps as per directions given by Secretary of Defense McNamara: they failed to do that.

Refining some manufacturing processes and redesigning some components solved these problems. The bolt was shot peened to increase its strength to deal with the higher cyclic rate. The disconnector was redesigned and made stronger to deal with the harder impact. The bolt catch was strengthened to halt the bolt carrier group of the higher velocity caused by the use of Ball propellant.

Other Modifications and improvements

As the war progressed, the rifle was further modified and improved. After first fielding, it was clear that these rifles were corroding. This is called “Intergrandular Exfoliation.” This is a chemical reaction in the aluminum caused by a combination of humidity, body perspiration and other chemicals that caused the receivers to flake off in layers and had a white corrosive substance appearance. This was primarily due to the receivers being made of the lower quality 6061 T6 aluminum forgings. Eugene Stoner himself had pled with Ordnance Corps to use 7075 T6 aluminum and was shot down until 1968 when production changed to the desirable 7075 T6 aluminum, which is used to this very day.

The lower receivers went through three generations as well. The original utilized a removable front pivot pin. The second introduced the captive front pivot pin, which visibly showed a raised area/rib that went straight back behind the front pivot pin and ended near the rear of the ejection port. The third was the addition of the magazine release button fence, which prevented accidental release of the magazine by dropping or dragging.

The bolt and bolt carrier had gone through some changes as well. The original AR-15 had a chrome plated bolt and bolt carrier. The XM16E1 used the same with the addition of the forward assist notches. This was a proprietary “hard” chrome plating process that was quite expensive. It was found that the chrome did wear off and chip and eventually corroded. It had also prematurely worn the internal dry film lube inside the upper receiver. The original purpose of chrome plating was to make it easier to clean. This it did, but there was a better way to go about this.

There are no remaining records that state the exact time when the chrome plating process ceased, but it is safe to say in the 1967 time period the chrome plating was dropped in favor a more durable and cheaper manganese phosphate which was black in color. The inside of the bolt carrier and carrier key remain chrome plated. Both the smooth side as well as the forward assist notched versions of the bolt carrier was produced in chrome plating and eventually both changed to the new finish. In 1966 Colt stopped manufacturing the smooth sided carriers due to lack of interchangeability with the XM16E1/M16A1 rifles.

Additionally, a new firing pin retaining pin was introduced. The original part was a machined retaining pin that came in chrome plated and manganese phosphate finish. A much cheaper cotter-type pin replaced this. The original was a much better component but there was another more inexpensive way to do the same job.

The Self-Cleaning Gun

With the purchase and distribution of more than 85,000 AR-15 rifles in Vietnam, there was not a single .22 caliber cleaning kit, operator’s manual or chamber or bore cleaning brush available. As recalled by Gene Stoner, the Army had no intention of buying the rifle so the government did not want to waste money on cleaning kits and manuals. The AR-15 was supposed to be an “interim” solution until they could get the SPIW (Special Purpose Individual Weapon) finalized and fielded. Therefore, the gun was touted as being self-cleaning. Troops were instructed that it was not necessary to perform any cleaning or maintenance on their weapons prior to going out on patrol or on a mission. Due to lack of reasonable maintenance guns would be fouled, firing thousands of rounds without cleaning. By not cleaning, the humidity and other environmental factors, the gun was even more prone to corrosion in the barrel and chamber. With the lack of availability of cleaning supplies, operator manuals and maintenance training, rifles were found to be in unserviceable condition in the hands of infantry soldiers. Many soldiers in the early part of the Vietnam War received training on the M14 rifle in basic training and when they arrived in Vietnam they were issued an M16. They received no instruction on operation and maintenance. With the introduction of Ball propellant, the fouling became more of a problem without maintenance

It was not until late 1966 that the Army began distribution (small) of the newly designed chamber brush which cleaned fouling out of the chamber as well as the locking recesses in the barrel extension. It was not until 1967 that large scale distribution of manuals, cleaning rods, bore and chamber brushes and lubricant were issued to the troops in the field.

Many have seen pictures, video coverage or heard stories of the flimsy M16 that was so fragile to dirt that condoms were placed over the muzzle to prevent dust from entering the barrel. Once again, a half-truth. The reason for covering the muzzle was to prevent water from entering the barrel. Due to the smaller bore, water enters by capillary action and is retained by surface tension. The gravity overcomes the surface tension in a larger .30 caliber bore and it will run out more easily. This was to protect more so from walking thorough streams and rivers and large amounts of water entering the barrel rather than a few drops of rain. This is a characteristic of a .22 caliber high power rifle. The best way to improve the barrel strength is to massively overbuild it to take severe pressures but the weight would become unacceptable. It should be noted that M1 rifles during World War II also had condoms placed over the muzzle during landings on beaches to keep water out of the muzzle.

The Forward Bolt Assist

Many believe to this day that the forward assist was an improvement to the rifle. The designers contested that it was in fact not an improvement but rather a detriment. Testing performed at Rock Island Arsenal proved this. They were able to demonstrate the detriment of forcing a cartridge into a chamber, and in particular a dirty chamber that can cause serious failures to extract and to open the bolt under adverse conditions. The forward assist was added by the request of the Army so the soldier would have some external link to the bolt carrier to manually close it. Odd, since even the M14 manuals say that you never force a round into the chamber. If it will not chamber, eject it out and load another. As Stoner designed the AR-10 as well as the AR-15, this external link was found not necessary. The forward assist was added to fill a psychological need, not a mechanical one. Eventually, it was added to all production rifles and is still in use today. It is an expensive addition to the rifle that has no practical purpose. Under extreme conditions such as being heavily corroded (not seen since they became chrome plated), or with heavily fowled chambers, the forward bolt assist will aid in chambering the round but will not affect the inevitable failure to extract. In firing hundreds of thousands of rounds out of M16-type weapons, this author has never had a malfunction that the forward assist would have cleared.

The Final M16A1

On February 13, 1967 the XM16E1 rifle was type-classified the M16A1 rifle. The final version would carry this weapon system for the next 18 years until the adoption of the M16A2. The final “A1” would have the enhancements including the magazine fence for preventing the magazine from being accidentally released, the forward assist, the 7075 T6 aluminum receivers, chrome plated bore and chamber as well as the new butt stock with the trap door to hold cleaning equipment. With the development of this rifle in full swing after the hearings, troops who entered into service in late 1968 encountered little trouble and the weapon went on to become one of the most successful small arms the world has even known.

The Carbine

With the introduction of the short barreled XM177 and XM177E2 carbines, a new realm of problems were found. The U.S. Government never officially adopted any 5.56mm carbine until the Colt M4. So, all the carbines used were small runs of guns not fully developed and no final Technical Data Package, and therefore; no true mil-spec like the standard rifle. Due to the shorter distance from the gas port to the bolt carrier, significantly more pressure is created in the carbine increasing the cyclic rate even more than the standard rifle. Multiply this with the use of ball powder. Major problems were more frequent failures to extract and bolt carrier bounce. With refinements such as the new M4 “H” buffer, the bolt carrier bounce problem has been solved and with enhancements to the extractor (stiffer spring and stronger buffer) and the use of the new “O” ring have brought the failures to extract problem to a halt.

Conclusions

Reputation is a funny thing. It is developed by many factors, rarely are they based on fact. It is subjective based on the individual’s perception of the weapon and subjected by prejudices. The AR-15 as introduced by ArmaLite/Colt was an excellent firearm but needed to be put through a proper development program before it was issued to the troops. Through this process, issues such as chrome plated chambers, cleaning equipment and modifications to use the alternate Ball powder would have been addressed. The political infighting between the Ordnance Corps, the U.S. military and congress caused many U.S. servicemen their lives by putting a weapon in their hands that was not properly developed, which Ordnance Corps was responsible for. Development of a weapon should never be conducted in the field. This agenda was for one purpose only, to protect their inferior M14 because it was home grown. Regardless that the M16 was ideal for the combat conditions in Vietnam, it was clear that the increased hit probability due to lightweight and low recoil, controllability on full automatic and ability to carry significantly more ammunition over the M14 were a clear advantage. High volume of fire was required in the dense jungles where clearly defined targets were rare. History has a funny way of repeating itself – One has to wonder what the M4 will compete against.

Acknowledgements

I would like to thank to Ken Elmore, President of Specialized Armament Warehouse for his contributions of both intelligence and materials for photography. An avid Colt AR-15/M16 enthusiast and collector, Mr. Elmore is also an instructor for Colt Defence LLC Law Enforcement Training Division. Specialized Armament Warehouse is one of the largest Colt parts dealers in the World located in Chandler, Arizona.

SAR Exclusive Industry Profile

For the first time in history, Bushmaster Firearms of Windham, Maine has allowed outside photographic equipment into their facilities. Small Arms Review was invited to visit Bushmaster Firearms to chronicle portions of the manufacturing process of their famous version of the Black Rifle.

In some parts of the world the word “Bushmaster” will conjure up images of large, venomous snakes. A member of the pit viper family, it is known for its lethality and is found in Central and South America. In circles of firearms enthusiasts and for members of the military and law enforcement, the same word is synonymous with quality AR-15 and M16 type rifles that are manufactured in the northern most state in New England.

Company History

Originally incorporated in 1973, Bushmaster Firearms concentrated their manufacturing efforts on the Bushmaster Arm Pistol, a survival gun designed for pilots during the Vietnam War. The Arm Pistol, along with a companion rifle known as the Bushmaster Assault Rifle utilized some parts from the M16 rifle family while employing an op-rod system similar to that used by the Soviet AK-47.

Following a company reorganization in 1980, Bushmaster Firearms, Inc. started to focus their efforts in selling AR-15 and M16 parts and eventually began to manufacture their own line of AR-15 and M16 replacement parts for sale. In 1983, the first complete rifles bearing the Bushmaster name were manufactured in Portland, Maine. Five years later the company relocated to their current location in Windham, Maine. Bushmaster Firearms, Inc. now owns a 52,000 square foot facility at their 19 acre business park and employs over 80 people at this location.

In 2002, Bushmaster established their Western Division in Lake Havasu City, Arizona. This division of Bushmaster Firearms, Inc. is dedicated to manufacturing a Carbon Fiber series of the AR-15 and M16 type firearms. This Western division now has over 25 full time employees and occupies 12,000 square feet to house their state of the art injection molding and CNC equipment.

Quality First

With so many companies currently competing in the AR-15 and M16 market, our first question was an obvious one; “What makes Bushmaster stand out in such a large market?” Their answer came as fast as the question was asked and was simple enough: “Q-U-A-L-I-T-Y.” Even though they have an extremely diverse product line of quality products, the general feeling at Bushmaster is that their quality control is their best selling point. When we asked for an example, we were directed to their Quality Control (QC) building and allowed to sit in as their barrels underwent their normal series of tests.

Bushmaster barrels are manufactured from Chrome-Moly Vanadium Steel or from 416 Match Grade Stainless Steel. Each process of manufacturing has to undergo numerous levels of testing in order to progress to the next stage of manufacturing. The barrel stock material is first drilled, button rifled and stress relieved. After undergoing a series of QC tests, all barrels that pass are turned to their intended profile and head spaced. Following another round of QC testing the barrels are chrome lined and tested again. All barrels that pass this stage go on to have the gas ports drilled and front sights indexed followed by a phosphate finishing.

In between each of these steps, the barrels are bore scoped and air gauged. When a barrel is bore scoped a technician runs an extremely powerful microscope all the way down the inside of the barrel. An image is projected onto a monitor and the technician actually visually inspects the inside of the barrel looking for flaws or abnormalities. In the process of testing the barrels with an air gauge, the barrels are pressurized and an indicator rod is slowly run through the length of the barrel watching for a drop or increase in pressure, indicating either a tight area or loose area not visible to the eye even while bore scoping. Any deviation outside of Bushmasters strict specifications will cause the barrel to “fail” and it will never see the next step in the manufacturing process.

To go a step further, even though the barrels undergo Magnetic Particle Testing they are also checked utilizing an Eddy Current. Magnetic Particle Testing is a process fairly common to AR-15 and M16 Barrel manufacturing and most people may have noticed the “passing marks” on their barrels in the past. The familiar “CMP” mark often seen would indicate Colt Magnetic Particle Testing and “BMP” would indicate Bushmaster Magnetic Particle Testing and so on. Magnetic Particle Testing is a process that checks the integrity of ferromagnetic parts by looking for microscopic cracks. During this testing, when a crack is present, an amount of magnetic flux will gather at that spot attracting magnetic particles allowing the flaw to be discovered. Testing with an Eddy Current goes even farther and allows the operator to electronically “look through” the metal checking for structural integrity, case depth and hardness while also allowing the ability to “see” cracks, pits, seams or otherwise invisible surface flaws. Finally, head spacing is checked on 100% of the Bushmaster barrels rather than just a random sampling.

Bushmaster utilizes a similar quality control regimen on all of their parts including their lower and upper receiver sections as they progress from raw material to the initial forgings to their finished and assembled states.

Once all of the individual parts have passed every step of quality control and final finishing, it is time for their assembly. All firearms assembly is completed in house with each gun going through several “assembly stations.” Each station specializes in one specific area of assembly and as the firearms ascend towards completion they end up at the test-firing portion of the facility. Every Bushmaster firearm is laser bore sighted and test fired before being shipped. Every semiautomatic firearm is fired a prescribed number of rounds in rapid succession and every round must feed and fire perfectly in order to pass this final test and go on to inventory for shipping. The test-firing requirement for each full automatic firearm is similar to this, with more rounds fired and the firing is also done in full auto.

A Diverse Product Line

Since the early days of the Arm Pistol, Bushmaster Firearms, Inc. has introduced and currently includes an enormous number of items in their product line, with over 50 different firearms and several hundred parts and accessories available for sale. From the typical AR-15 and M16 style firearms used as the primary service weapon of the United States Armed Services for over 40 years, to the newest Carbon Fiber firearms technology, Bushmaster strives to have something for everyone. Their current offerings range in caliber from .22LR variants all the way up to .308 (7.62x51mm NATO) models and range in size from pistol configurations up to their 24-inch heavy barreled varmint series.

The Bushmaster M17S Bullpup Carbine may be one of the most unique firearms in the Bushmaster product line. The M17S affords the shooter a 21.5 inch barrel on a package with an overall length of only 30 inches. It is a short stroke piston, gas operated semiautomatic rifle and is chambered in 5.56x45mm. It utilizes standard AR-15/M16 magazines.

As well as servicing the U.S. commercial firearms market, Bushmaster Firearms, Inc. currently manufactures arms for U.S. law enforcement, governmental agencies and foreign military forces. Short-barreled rifles, law enforcement and post 1986 dealer sample machine guns are all available with prior BATFE (and at times, State Department) approval.

Bushmaster Firearms Inc.
999 Roosevelt Trail
P.O. Box 1479
Windham, Maine 04062
(800) 883-6229
www.bushmaster.com