When the phone rang in my office at Knight’s Armament Company the caller identified himself as Christos Epperson and he was calling to inquire about Reed Knight’s Institute of Military Technology (IMT) He also has a question regarding a 9mm United Defense Model 42 made by Marlin. He tells me his Uncle George fought with the resistance against the Germans on the Greek island of Crete during World War II, and specifically about connecting magazines together to maximize ready firepower.

Christos sends me a quick email of his Uncle George, holding the Marlin and sure enough, magazines are joined at the front. Christos explains that his uncle realized that taping them together wouldn’t work, so he found a local blacksmith that welded them together. Was this the first incidence of such a field modification? Christos tells me he’s made a documentary about the Cretan invasion and the resistance movement and will send me a copy.

When the Germans invaded Crete they decided to try something altogether new in the art of warfare. Crete, Greece’s largest island, may be thought of as a huge “aircraft carrier” in the middle of the Mediterranean Sea and occupying it was a major strategic move for any army. To capture it, the military tactic the Germans used is now known as a “vertical envelopment.” The plan called for an assault on the island using a huge force of paratroopers and gliders carrying combat troops.

Allied forces stationed there, mostly British, Australians, and New Zealanders, would be far outnumbered and would be forced to leave the island or be killed or captured. The Cretan population had no local army as most of their young were in the Greek army fighting on the Albanian front. With nowhere to go and very little in the way of small arms and ammunition, the Cretans would be expected to surrender without much of a fight. After all, the Germans took the entire nation of France in just one week. With seasoned troops, modern equipment, and this new military tactic, Crete was expected to be under German control in a few hours.

However, the Germans ever in for a huge surprise. Had they checked their history books more carefully, they would have learned that Crete had been conquered many times by superior forces including the Venetians, Persians, and Turks. After fierce fighting, all of them eventually claimed the island as their own, but none of them ever really had full control. Every day each member of the occupying force was looking over his shoulder, lest his throat was slit by a swarthy local. Throughout history, every Cretan male has kept a dagger sheathed either in his belt or his boot and is well-schooled in its use.

For all the planning, superior firepower, and precise execution of the vertical envelopment, Crete did not fall in a day, or even a week. It was ten days after the invasion the Germans were convinced they had secured the island as theirs. But the Cretans had their own plan. There would be another day, the 11th day, in fact. On that day the Germans would pay.

I review the picture of the M42 with Reed Knight, and as I expected he’s got a wealth of information about it and shows me a sample in the IMT collection. Reed says magazine connection by using tape occurred well before this picture was taken, but he believes it may be the first time magazines were welded in theater.

Upon arrival of Christos’ documentary, The 11th Day, I sat down to watch it and was stunned. The dialogue is spoken by the actual people the story is about. Somehow, Christos had located enough of them still alive, and still able to recall the stories – truly fascinating.

So who is Christos? Where did he come from and what’s the story with this video? What else is he working on? There were many questions that prompted Christos to visit the IMT, which gave us the opportunity for this interview:

George: What made you decide to make a documentary about the Cretan invasion?

Christos: My family is from Crete. My aunts and uncles, all brothers and sisters, were spies for the Cretan resistance forces. When my aunt, Eleutheria, was caught stealing German maps for them, she confessed to working alone so that her two brothers and sister would not be charged. She was tortured and executed, and her three siblings were sent to concentration camps. So you see, this story is a part of my family’s history.

George: Doesn’t a documentary like this require a lot of time for researching facts, as well as finding and interviewing survivors?

Christos: Most of a documentary is research and World War II survivors are becoming fewer and fewer. I had to work fast, but even at that, script to screen took me 5 years.

George: Your documentary was very realistic. Where did you find reenactors and equipment?

Christos: There are good sources in Hollywood for reenactment supplies. Some items, like the pants, I had to have made. Others were very difficult to obtain, like German paratrooper boots with laces on the side. Having them made was cost prohibitive. As for the reenactors, believe it or not, most of them were the grandchildren and other relatives of the actual resistance fighters. Cretans are very patriotic so finding volunteers was not at all difficult. That is, except for the Germans. Cretans flatly refused to play them so I ended up down at the beach, recruiting tourists.

George: …and the guns?

Christos: I took some propane firing MG42’s and the rest were rubber Mausers, Lugers, and sub guns. It was a nightmare getting them into Greece and a worse one getting them back into the U.S., even though I had all the properly executed paperwork.

George: Tell us about the resistance and guns they used.

Christos: There were weapons on Crete when the Germans arrived. Most were really old – some were even muzzleloaders, but they used what they had. The German paratroopers were not armed when they jumped. The guns and ammunition were dropped separately, and it didn’t take long for the Cretans to figure that out. At that point it became a race between resistance fighters and the Germans to be first to arrive at the crates when they landed.

The Cretans were aided by a few British, New Zealand, and Australian troops who remained trapped on the island, and of course, these troops had their standard issue weapons. After the resistance force became an organized unit, the allied command realized their effectiveness and air dropped them more guns, ammunition, and supplies. British intelligence became very active on the island and sent them in a leader, schooled in guerilla tactics, a man named; Major Leigh Fermor. I was fortunate enough to locate him and interview him for the documentary.

George: What did they find as the most and least effective weapons?

Christos: For close-in work, they liked the M42’s that were dropped by the OSS. For the most part these were country boys who grew up hunting and shooting in the Cretan mountains and learned marksmanship from their parents. They took a real liking to the German K98 and used it as a precision rifle removing one invader at a time. They used cover and concealment tactics taught by the military today. As for least effective, they had some machine guns but as they were so badly outnumbered, they preferred lightweight weapons they could use in hit and run type operations and of course, the Mausers for accurate fire.

George: Give us some examples of the effectiveness of the resistance.

Christos: The German troops were badly needed on the Russian front, but were bogged down on Crete fighting the resistance. The invasion of Crete was Germany’s first major defeat of the war, with half of the 8,000 elite airborne assault troops decimated.

Bold raids were made by resistance fighter on airfields where a large number of German aircraft were destroyed. The Brits, New Zealanders, and Aussies worked effectively with the Cretan resistance. Inspired by the treachery of the Germans and emboldened by success after success of raids and ambushes, the resistance conjured up new and more ambitious plans. At one point they actually captured the German Commander and Chief of the German forces on Crete, General Kreipe. They shuffled him off to North Africa for intense interrogation – the only kidnapping of a German general in the entire war.

Besides these hit and run raids, they also found that when the Germans turned the 88mm guns on them, their tactic was to move closer to the big guns and pick off their operators with precision small arms fire.

George: I understand women, children and even priests played major roles in the resistance. Tell us about that

. Christos: Young children focused their play around the Germans and recorded whatever was of interest to the resistance. The allies had intel on the contents of every ship that offloaded cargo onto the island, including the number of crates and their markings. Teenage girls and women fought alongside the resistance or made frequent trips to bring them food and supplies.

When the resistance hatched the plan to capture the German general, they had stolen some German uniforms, but the insignias weren’t right. Local women, anxious to do what they could to aid the resistance, volunteered to embroider new ones that matched the ones worn locally. One old man told me he was only nine when the Germans invaded. Every day he would roll heavy rocks out into the road, and every day the Germans would have to stop their trucks and roll the stones back. He told me that at his age, he couldn’t do much, but he could at least slow the Germans down. My Uncle Theo was the Orthodox Bishop on the island by day, but by night he used his church to run an effective gun smuggling operation.

George: You said a surprising thing happened when you showed up on Crete with dummy guns for the reenactors. What was it?

Christos: Whenever I brought out the replica guns to do the filming, the Cretans didn’t want to have anything to do with them. They preferred to use their original guns – you know – the ones that were actually used by the resistance.

George: Come on! The Greek government only allows shotguns for civilian ownership.

Christos: There is an old Cretan saying about the importance of their guns. A Cretan man will tell you: “If I had to pick between giving up my wife, house, or my gun, I’d keep my gun, because with that, I can get the other two back.” I heard this often while I was there, and from different people.

George: You’re telling us these guns are still around today?

Christos: Cretans historically pass them down to the oldest son. Whenever I went up into the villages and we started talking about the invasion, the resistance and my documentary, out came the guns. These guns drew blood in the defense of Crete and have both a symbolic and a defensive use. The Cretans wanted these guns to be used in the documentary.

George: So, this recent photo of your Uncle George holding the Marlin at the war memorial; you’re saying it’s the same one he’s posing with during his resistance days?

Christos: Yes, this gun was dropped by the OSS and was very popular with the resistance as it could use captured ammunition because it was chambered for 9mm, which was available from the Germans. It was developed by United Defense and manufactured by Hi Standard and Marlin. They were very well made. My Uncle George’s was a Marlin and he said it shot tight groups and he never had a problem with it.

Besides the M42’s I brought, there were plenty of Greek Mausers that literally came out of the Cretan woodwork. One was even nicely decorated with silver icons. The one that surprised me the most was a Bren gun. They insisted on taking me to the exact spot where it was air dropped by the OSS.

George: It seems not only the guns were sacred but the battlegrounds as well.

Christos: It was even more complicated than that. Most of the land was under control of a monastery. I had to get special permission, so I brought along a priest and my Uncle George to help me negotiate. People kept telling me I was crazy as no one goes up there. The last ones who did were the Germans, and we know it didn’t work out very well for them! I gave the monks 13 space heaters and they gave us 3 shepherd guides. Two of the camera men were non-Greeks and had to get baptized with Cretan names.

My Uncle George Tzikas had a personal reason for finding one spot, and to our amazement, he took us right there. It was a place where he had a shootout with a couple Germans. They kept shooting at him but kept missing – hitting the tree behind him. Just when he had one of them in his sights, he squeezed the trigger but the round was a dud, so he extracted it, chambered another round and maneuvered around until he finally got them both.

George told me he had recurring nightmares about that event, only it was a variation that included the dud round but ended with him, not the Germans, getting killed. He insisted we use our metal detector to find the dud, and we did! Since he’s recovered that round, he says his nightmares have gone away.

George: What about pistols?

Christos: It was important for every resistance fighter to carry a pistol, a grenade, or both. The pistol wasn’t for offensive use, though. The resistance fighters had the attitude they were dead anyway and they knew what awaited them if they were captured. The pistols were to be used on themselves if that time came, hopefully taking a few Germans with them.

George: How do our readers get a copy of your documentary?

Christos: The best way is through www.crete1941.com

George: Tell us about your next project.

Christos: I’m working on a documentary called: Outpost Harry. During the Korean War, there were three outposts: Tom, Dick, and Harry. Five battalions – four American and one Greek – took turns defending the outpost, and each of them was overrun with Chinese. When the Greeks took their turn, 3,000 Chinese were held off by 150 Greeks and American soldiers. They became known as the “Sparta Battalion” after their commanding officer told them, “If 300 Spartans could hold off 100,000 Persians, a hundred and fifty of us should have no trouble against a few thousand Chinese.”

There is a gymnasium at Ft. Benning named Outpost Harry to commemorate the bravery of the men who fought there.

George: What did the survivors tell you about the guns used in this conflict?

Christos: Each time they were overrun, they called in artillery on their own position. These barrages resulted in huge amounts of airborne dirt going airborne. Many of the veterans told me about their guns jamming as a result. I’d be interested in finding out more about that and what we’re doing today so that doesn’t happen again.

George: Roger that. We’ll be looking forward to seeing Outpost Harry when it’s done and we sincerely appreciate you taking the time to talk with us today – thank you.

By Kevin Dockery

Few firearms manufacturers have proven themselves as successful as the Knight’s Armament Company (KAC). In just 25 years, C. Reed Knight, Jr. has taken his company from being a modest but skilled R&D shop into a unique modern military supplier. The structures that have held the shops and offices of KAC have changed from being a small two-story building in an orange grove to a sprawling complex of buildings, bunkers, and range facilities with the main plant having more than 400,000 square feet of work space.

The new location of the Knight’s Armament Company is in the old McDonnell Douglas Astronautics facility on Columbia Blvd. in Titusville, Florida. The Titusville plant is only a relatively short drive from central Florida and the huge convention center at Orlando. It is when the SHOT Show is at the Orlando center, such as it was this year, that KAC takes advantage of their facility’s location, and the invited guests of Mr. Reed Knight can take advantage of his own style of southern hospitality.

Even in the middle of January, central Florida can be a hot place, especially for writers and guests who have come down from the colder (much colder!) northern climes and countries. The well-upholstered and air-conditioned transportation put on by Knight’s made the afternoon trip to Titusville a quick and comfortable one. The crowds from the buses were filled out even further once at the plant by the number of people who arrived in their own vehicles. Any way you had arrived, the trip was well worth the time with what was waiting for everyone at Knight’s.

After a quick organization, and the filling out of the more and more common legal forms and releases, the writer community and dignitaries were invited to try out a number of products from both KAC as well as other manufacturer’s. It was trigger time again.

When the Shot Show was last in Orlando a few years ago, Reed Knight held his first open house at the Titusville facility. At that time, the primary guest of honor was General Mikhail Kalashnikov himself and an extensive demonstration was put on of the Knight Armament’s line of products. This year, the open house was a much larger affair and General Kalashnikov was unable to attend. Even the good general might feel that he missed out as instead of witnessing the Knight products, writers and others were invited to try them out for themselves.

Just moving around the huge facility was an event in itself with vans moving groups of people from one firing site to another. Part of the reason for this was the different ranges needed for the other companies that were also taking part in the KAC open house.

The first of the ranges visited was the close-in firing demonstration held by Lewis Machine & Tool Company of their M16 variations. One of the highlights at this position was a chance to fire the CQB version of their Monolithic Rail Platform upper chambered for the powerful 6.8mm round. Having seen combat with Special Operations Forces in Afghanistan, the 6.8mm round with its heavier bullet is proving to be a valuable asset, one worthy of further examination. With the radical rail system patented by LMT and machined out of a solid aluminum forging, the strength of the system is phenomenal, and the accuracy that comes with that strength is also world-class.

The LMT 6.8mm upper Close Quarters Battle specimen available for the demonstration was quick to handle while remaining controllable, even on full automatic fire. The future of the 6.8mm round is still vague at best. But no matter the caliber, Lewis Machine & Tool has a winner in their solid Monolithic Rail Platform uppers as well as their own line of receivers and complete weapons.

Transport took the groups finished with shooting at the first range to the next open range where a new line of rifles from Knight’s Armament were waiting for use. Even though we were all looking forward to examining the new weapons, it was hard not to be impressed with the layout and facilities of the Titusville compound. There were rows and rows of huge concrete and earth bunkers, leftovers from the days that McDonnell-Douglas Astronautics Company loaded up Dragon missiles on the site. The massive bunkers would hold up to the ignition of enough ammunition to satisfy the most jaded of SAR readers, while still leaving enough room to outfit a small country – or shoot up on a Knob Creek weekend. If there is an expansion into heavy ordnance in Knight’s future, the Titusville facility has more than enough assets on hand to take care of any job short of making solid-fuel space-shuttle engines.

At the next range were some very familiar weapons, with new twists that were not immediately apparent. The SR-15 series of rifles and carbines are upgraded AR-15 style rifles with a number of improved features developed by Knight engineers. On the table were a pair of SR-15 E3 URX (Upper Receiver Extending) carbines, both with KAC folding iron sights and attached Harris bipods. Inside, the carbines boasted dual extractor springs, redesigned locking lugs with increased strength, and a number of other new and patented features. The overall design of the SR-15 proved such and improvement over the original design that it was adopted as the basis for a heavy-barreled 5.56mm sniper rifle, the Mark 12 Mod 1 Special Purpose Rifle. The URX E3 carbines were to prove only slightly less accurate, and nearly two pounds lighter, than the GI Mk 12 Mod 1 rifle, but at the short range available to the shooters at that table, the guns showed themselves to be more than adequate.

It was at the last range that the wait was longest to fire the weapons, and the reason was obvious enough. To a long-gun shooter, the last range area held a real treat. On the benches were premier examples of the KAC engineers, and the lasting legacy of Eugene Stoner.

Seven years ago, the Navy SEALs adopted a modified version of the SR-25 rifle as their new semiautomatic 7.62mm sniper rifle – the Mark 11 Mod 0, a replacement for the venerable M14-based sniper weapons still in the racks. On the bench was a single example of a Mk 11 Mod 0 rifle, set up with both a sophisticated electro-optical sight and a long Knight-produced sound suppressor. The optics was a CS6000 thermal imaging sight capable of detecting human activity out to a range of 2,200 meters. All-in-all, a very serious weapons system.

Lined up next to the Mk 11 were the two newest versions of the SR-25, the recently adopted XM110 U.S. Army Semi-Auto Sniper Rifle System (SASS). The XM110 has a twenty-inch match grade 1:11 twist heavy barrel, as does the Mk 11. But the muzzle of the XM110 barrel is threaded to accept a flash suppressor. The trendy desert tan color of the XM110 rifles also made them stand out, but all the weapons shared the same basic characteristic – long range accuracy combined with a quick follow-up firing capability.

Firing some of the best weapons available might prove enough for most to spend an afternoon away from the Shot Show. But Reed Knight’s rendition of southern hospitality required that he offer much more. Underneath huge tents in the parking area near the main building were set up long rows of tables, just what were needed to partake of the excellent barbeque served up by the caterers. Keeping with the overall country-western theme of the day, Reed Knight, along with his staff and sons, were wearing western outfits, complete down to Colt single-action revolvers riding in low-draw holsters. In the background was both a mechanical bull for the more adventurous among the guests, as well as a much safer Country-Western band, the Bama Band, who were twice nominated for the Academy of Country Music’s Band of the Year Award and were for 20-plus years the touring band for superstar Hank Williams, Jr., that fired up their music in the sunset hours.

But it was the tour of the KAC main plant that really drew the crowds. On the plant floor were Mazak machining centers – quarter-million dollar chunks of computer-controlled precision. And there were rows of the big machines stretching out across the plant floor. Each machining center is capable of turning out identical parts for as long as needed, and then they can be reprogrammed to produce other components with a minimum of fuss, given skilled staff. And Knight’s Armament has 300 personnel making up that skilled staff manning the 400,000 square feet of floor space.

To help the production machines make their parts at KAC is a new Fanuc robotic arm. The bright yellow arm was twisting and turning through a complicated measuring protocol, dancing the same moves over and over for the on-looking crowd.

On the production floor, rack after rack was filled with parts in various stages of manufacture. The area was quiet for the open house, but the bins and racks of parts stood in mute testimony of the demand for Knight’s components and assemblies to aid the United States and the Global War on Terrorism.

There is something to be said for the success of a design when you see hundreds and hundreds of parts to make up the Knight Rail Adapter Systems (RAS) that are seen on many of the weapons serving in the hands of our troops in Iraq and Afghanistan. The basic idea for the RAS came to Reed Knight when he watched footage of our troops in Grenada back in 1983. A long-time competitive shooter, Reed saw the guns in the hands of our troops with flashlights duct-taped to the forearms. Knowing that there had to be a better way to secure the illumination and aiming devices desired and needed by the troops, Knight and his engineers came up with the rail system, now used in every branch of the service.

Other components for successful Knight designs filled the bins on the floors and tables, but it was the second floor that held the crown-jewels of the tour. The Knight firearms library holds an extensive collection of weapons for study, many of them museum-class specimens in their own right. Taken as a whole, the library of firearms can easily compete with a number of large weapons museums around the world. Only these weapons are for study to help develop new designs to keep American arms technology in the lead for many of the world’s militaries. The Knight Working Reference Collection is incredible to experience.

The large number of guests at the open house had to be broken up into smaller groups to go through the plant and finally visit the collection. Since a number of unauthorized photographs of part of the collection have been posted on the Internet, cameras are strictly forbidden for the visitors to the collection. For the readers of SAR, Reed Knight graciously allowed this writer to bring a camera into parts of the collection to illustrate this article.

In the hallway leading up to the main room housing the bulk of the library, glass walls show the interiors of two side rooms housing two very special collections.

With justifiable pride, Reed Knight stood in front of the E. M. Stoner Memorial Gallery. Not just any firearms were contained in the gallery, it was a tribute to the firearms genius and hard work of Eugene Stoner, a designer and engineer well known to any who study the art of modern weapons. On the walls of the gallery were unique specimens of Stoner’s designs, most of them one-of-a-kind prototypes.

Opposite of the Stoner gallery was another room holding the examples of the products and weapons made by Reed Knight and his people over the years. A centerpiece of the KAC Shot Show booth was 6x35mm KAC Personal Defense Weapon. On the walls of the gallery were specimens of that weapon along with a number of others. When Reed was asked which of the pieces was his favorite, he reached over and pulled down a Mk 11 rifle, a particularly beat up and badly damaged piece.

The reason for Reed’s pride in that particular rifle? It had taken its damage in combat, serving in the very capable hands of a Navy SEAL.

SAR would like to thank Reed Knight and his son Trey, as well as their staff, for the wonderful opportunities they have afforded the small arms community in the past years, and to salute their commitment to the pursuit of knowledge and future development in small arms. The Knights have helped countless designers, writers and researchers over the years, and the readers of many firearms magazines, especially Small Arms Review, have benefited from this commitment to academic research. During the event at Knight’s, over 1,400 people experienced the hospitality and received a good old fashioned Barbecue in addition to their test firing demonstrations and tour of the plant and the Knight Collection. Those who toured the Collection were treated to explanations and anecdotes from Reed, Trey, George Kontis, Col. David Lutz and other employees of Knight’s, and SAR’s Dan Shea was also drafted/volunteered to serve as a guide for several tours as well. It was clear that everyone involved was proud, and indeed humbled, to help the attendees experience the amazing depth and focus of the Knight Collection. Again, SAR would like to thank the Knight’s for their generosity in sharing the history and knowledge they maintain in their Collection, and indeed, for keeping the torch alive in an age when political correctness has threatened our national security by chiseling away at our martial knowledge.

“It really goes back about twelve or thirteen years when Gene Stoner – rest his soul – and Reed Knight, my boss, got together and Reed gave Mr. Stoner an engineering and production facility for him to fulfill some of his dreams. And one of his dreams was a rifle like the SR-25. Soon after building the first SR-25 some of our special forces took them to Somalia and that’s where the SR-25 started to make its combat reputation. Soon after that the barrel was shortened from 24 inches to 20 inches and other things were changed and improved and that’s where the MK 11 comes from. That became the MK 11 Mod 0 in the year 2000. Now, five or six years later you’ve got the XM110 so there’s a clear sequence.” David A. Lutz, VP for Military Operations, Knight’s Armament Company

The fast-paced urban combat environment that quickly evolved in the Global War on Terror created shooting challenges that weren’t being satisfactorily met by the Army’s standard issue bolt action M24 Sniper Weapon System or by the limited-issue accurized M16 variants and reworked M14s. So many snipers were reporting dissatisfaction and their need was so urgent that the Army’s Program Executive Office Soldier fast-tracked a solution as authorized under the Soldier Enhancement Program. A formal Presolicitation Notice for what was soon designated as the XM110 SASS was posted on 17 Nov 2004:

“The US Army ARDEC…has a requirement for a 7.62mm semi-automatic sniper system (SASS) capable of delivering precision fire primarily on anti-personnel targets out to 1000 meters…. The offeror shall submit five (5) bid samples at no cost or obligation to the government…. The first fifteen (15) of the thirty (30) SASSs will be delivered with spare parts 30 days after contract award.” Solicitation Number W15QKN-05-R-0433

The actual solicitation followed barely two weeks later, nearly a hundred pages of highly detailed requirements in which the Army invited all comers to submit a definition-stretching COTS/NDI (Commercial-off-the-Shelf/Non-Developmental Item) for a comprehensive evaluation. Five manufacturers bravely entered the arena but when the slugfest ended Knight’s was the winner announced on 28 September 2005. Their modified MK 11 Mod 0 has earned a five year contract and recent statements by program officials indicate the Army intends to buy and deploy thousands of complete systems as fast as Knight’s formidable manufacturing facility can turn them out.

A few months after the award announcement, when the runner-up’s formal protest had been dismissed after lengthy review by the General Accounting Office, the government bureaucracy’s innumerable administrative details had been worked out, and the production process was smoothly underway, Knight’s invited SAR in for an exclusive tour of its impressive new headquarters and enormous manufacturing complex on Florida’s “Space Coast” in Titusville.

While there we got the opportunity to conduct an in-depth interview with a key player in the fast and furious process that resulted in this tremendous victory for snipers in the Army, as well as significant product improvements that are already beginning to benefit those in other branches of the US Armed Forces.

David A. Lutz, a retired Marine Lieutenant Colonel with a well-deserved reputation for straight shooting in every sense of the word, is Knight’s Vice President for Military Operations. He was instrumental in development of the Stoner-Knight SR-25 into a military sniper system that has achieved tremendous success with Navy SEALs, Army Rangers and other elements of US Special Operations Command. Lutz worked closely with retired Navy Lieutenant Commander Michael Warner, who skippered Knight’s winning team in the SASS competition as Program Manager.

What follows are key excerpts from more than two hours of in-depth discussion, giving a fascinating look from the contractor’s perspective at the complex process that has led to selection of the Army’s newest sniper rifle.

SAR:The Army’s solicitation ran to nearly a hundred pages for an end-item system that was supposed to be pulled almost literally off the ready rack. Comments?

Lutz: ‘Non-Developmental Item’ is supposed to be the short cut to fielding the 90 percent solution to the guy in the field immediately. It seems to me that the generals know what NDI is, they know that’s what’s needed because it supports the troops they command. But once the program gets launched the bureaucracy below the general officer level is the same as it was twenty or thirty years ago.

There were things on nearly every page that you had to do; whether it was produce a gun or produce a piece of paper or produce a plan. If I can make a comment here, unless you’re a pretty good size company and have some pretty extensive depth of skill sets, you’re not going to be able to address these ‘NDI’ solicitations that require such boilerplate.

SAR: How did the Army’s experience with the M24 system influence the initial solicitation and subsequent modifications?

Lutz: As originally conceived – I think by the Army Sniper community – it was supposed to be a total package to include a night scope, a new spotting scope. So they put everything they wanted into it. They even made reference to a ‘sniper support kit’ that would have all these bells and whistles that you’d see – let’s say – at the S.H.O.T. show. A spirit level on the scope so you could make sure you’re not canted. A little wind direction velocity meter that you might see at Camp Perry.

Well, when the solicitation came out for this XM110 some of those extra things, so to speak, were not included in the solicitation. I think the Army wisely pared down that list.

What they were really interested in was a rifle. Part of the requirement was for that rifle to have what’s now the standard Picatinny Rail. We put such a rail system in the year 2000 on the MK11 Mod 0 so the real estate of the rail could be out front of the daytime zeroed sniper optic and could accept an attachable night sight that would not require the sniper to remove his day scope and possibly lose his zero.

SAR: You’ve shown us in side-by-side comparison that Knight’s winning XM110 is essentially the same as the SR-25 and the MK 11 Mod 0. Same upper and lower receiver, bolt mechanism, direct gas tube system, match grade Obermeyer barrel, and so forth. But significant modifications had to be made in secondary areas. Take us through those changes in the rifle from muzzle to buttstock, starting with the Army’s requirement for a separate flash suppressor and a sound suppressor.

Lutz: The MK 11 Mod 0 does not have, never did have, a flash suppressor. When the Navy SEALs need flash suppression they install the sound suppressor that comes with the system. Our sound suppressor I guess in a way is the world’s best flash suppressor as well because it masks all the flash.

A flash suppressor was not a COTS item (for the SR-25) so we had a very short period of time to adapt the MK 11 barrel which we use in the SASS but we thread it and we install a flash suppressor we designed – a very basic flash suppressor – to meet that Army requirement.

That in turn had an effect on the sound suppressor we manufacture for the MK 11. The flash suppressor makes the MK 11 barrel an inch and a half longer and it also increases the diameter at the muzzle so a new sound suppressor had to be designed and manufactured for the Army SASS. Now the working part of the suppressor – the baffle stack that’s in front of the muzzle – is identical so you get the same noise attenuation but it’s an inch and a half longer at the rear because of the impact the flash suppressor had on it.

The way the suppressor attaches to the rifle is identical. There’s two points of contact, one at the muzzle and the primary one back on the gas block where there’s a drop latch which secures it. And right behind the gas block we’ve got the rail system.

SAR: Any changes there?

Lutz: The URX – Upper Receiver Extending – rail system for the SASS is new and in fact better in some ways than the MK 11. Instead of there being some sort of slip nut between the receiver and the rail system as a means to attach and secure it, in URX form the rail system screws directly onto the upper receiver and then as the barrel nut is torqued the upper receiver and the rail become one piece. It’s much more rigid, you have the timing across the top of the rail precise with the MIL-SPEC as opposed to the MK 11. So it’s better in several respects.

Also unique to the URX is that the bottom rail is detachable by the operator. This allows the operator to take that lower rail off and clean debris, dirt, mud from around the outside of the barrel.

We developed the URX, ironically, for a completely different SR-25 requested by a certain part of the military that already had MK 11s. If possible it should be just as accurate but something that was lighter weight, easier to carry that they could use for patrolling, reconnaissance missions and perhaps even close quarters battle. So we developed the SR-25 Battle Rifle with a fourteen and a half inch barrel and a telescopic buttstock. In an effort to take as much weight out of it as we could, we developed this URX forend.

All we had to do for the SASS is make that Battle Rifle’s URX forend long enough for the twenty inch barrel SASS rifle. That was pretty easy for us to do.

We put our standard MK 11 folding rear sight on the gun. It had to have backup iron sights adjustable from two hundred to six hundred meters. But they wanted the front sight to be integral to the rail, so the SASS – as opposed to the MK 11 which has an accessory, a true clamp mounted flip front sight – so we very quickly came up with a design to make the front sight integral to the URX rail.

SAR: The Army wanted an ambidextrous selector but didn’t specify an adjustable trigger mechanism.

Lutz: The requirement asked for an ambidextrous selector and we make one of those – we’ve made it for the SR-25 for awhile so that was pretty easy to do.

Though the Army didn’t ask for an infinitely adjustable trigger, it’s common for snipers who are used to bolt action rifles to have a trigger that is adjustable in eighteen different directions. We use a very simple, reliable two-stage trigger. They’re all set here in the factory at four and a half pounds and that’s as much as they need. I know that some precision shooters like a lighter trigger pull but I think most of that experience is based on single stage trigger use.

With a two stage trigger you have an initial take up of about an eighth of an inch, in actuality uses up about a pound and a half of that four and a half pounds. So for your final squeeze your brain’s forgotten about the one and a half pounds you took up the first stage with so as you squeeze the trigger it really just feels like three pounds. It’s something you have to try and I’ve found when most marksmen actually try the trigger they think it’s fine. And when you think about the fact it’s not going to fall out of adjustment or an operator will find out subsequently it is very difficult to change those adjustments. Making it more ‘fail safe’ is the way to go.

SAR: Stock length and cheek weld are also important to precision shooting.

Lutz: The MK 11 did not have an adjustable buttstock and it was required by the Army that the buttstock be adjustable for length. In order to start off at the shortest distance possible, instead of using a standard M16A2 rifle stock that the MK 11 uses, we went back to the Vietnam-era M16A1 stock which gave us a five eighths inch shorter overall package. Our adjustable buttstock extends from that for about two and a half inches so you’ve got quite a bit of length adjustment.

Now it was desired by the Army that the stock also have an adjustable cheekpiece and it have adjustments for cant and what’s called castoff. Because those things were ‘desired’ – not required – and because we didn’t really have time to adequately address them in a sound engineering design we didn’t do any of that, we just did the required length adjustment.

Our XM110 is an M16 based design that Mr. Stoner made in what he called a ‘straight line design’ with the stock already at the proper height for a scope if you have the right height scope mount, about an inch and a half. So the contrivance of an adjustable cheek piece is really not necessary with this style rifle as long as you have the correct height ring.

And also because of the feature of the M16’s charging handle that’s right on top of the stock when retracted. There can’t be any raised portion in that four or five inches right behind it.

Our charging handle, by the way, is based on Dave Dunlap’s “Gas Buster” design that we pay a royalty to PRI (Precision Reflex Inc.) for permission to use. It has a number of important benefits, particularly operator comfort when the sound suppressor is attached.

SAR: Is the system’s day scope an “off-the-shelf” Leupold?

Lutz: One of the hardest nuts to crack was trying to meet all of their required capabilities for the scope and then to address some of their desirable features. One of the things they obviously wanted was a variable power scope that had one half of a minute of angle (MOA) adjustments in elevation, but also had the characteristics of what most people call a ballistic cam, or an elevation knob graduated in meters. In this case it had to be graduated from 100 meters to 1,000 meters.

Now there are lots of scopes graduated in meters; particularly the Leopold Tactical Series with what they call the M3 turret. But those clicks – increments on the knob – are all one MOA. To get half MOA clicks you have to accept a knob that rotates 360 degrees twice so it becomes a two turn system. Now the way Leupold engineered this, once the rifle and scope are zeroed, you can rotate the elevation knob about two and a half total turns.

The Army also required the whole rifle to be a desert tan dark earth color. Leupold didn’t make a scope that color at the time. They went right to work and now the current scopes are all hard anodized dark earth. This is defined in the Mil-Spec narrative as ‘darker than a cardboard box but not as dark as chocolate.’

The scope also had to have an illuminated reticle. Fortunately, one of the newer lines of the Leupold Tactical Series scopes are their three and a half to ten power variable with the TMR, Tactical Milling Reticle. It’s illuminated for low-light shooting, powered by the same battery that’s in the Army’s M68 Close Combat Optic – what you and I call an Aimpoint.

We had a lot of options for the scope mount when the solicitation came out but we wanted to improve our return to zero capability and make it simpler. So instead of using a pair of parallel split rings and all those parts and pieces, we came up with a new one piece scope mount that as a product improvement has potential to become a quick detachable design.

The two half inch nuts and two clamps are standard format types of scope attachment means that (snipers) use their half inch T handle 65 inch pound torque wrench that’s included in our tool kit. But the way the mount’s designed, you can take the two nuts and the two clamps off, put a single clamp on that side with two wing nuts. By virtue of the torque you can get from the wing nut and the longer one piece clamp you can get the same return to zero without resorting to the wrench technique. So we’ve got plans for that mount beyond the SASS.

SAR: The rifle we just photographed on your range is remarkably uniform in ‘Flat Dark Earth’ color from end to end despite the differences in what’s underneath – steel suppressor, aluminum receiver, synthetic stock, etc. How is this done?

Lutz: One of the challenges to make the rifle this brown color is that we’ve been working for several years trying to get the right dye mix to anodize different aluminum parts this ‘dark earth’ color. Sometimes you’d come up with a perfect color, other times you come up with a color that was too much of a gold tone. And if it wasn’t a gold tone when it was freshly done, as soon as you’d put the gun together and had some oil on it this oil made the light tan anodization look gold.

So once the rifle is all put together we mask off some areas and paint – bake on paint – a dark earth MIL-SPEC color to the whole gun. That’s how to deliver the gun in a nice uniform appearance. You also get quite a bit more corrosion resistance because you’re painting right on top of pristine anodization, or in the case of the barrel, pristine mag phosphate.

SAR: The system comes complete with two hard cases full of accessories, tools and equipment. Any particular challenges to pulling all these together?

Lutz: The Army SASS required a system case that had enough room in it for everything that was listed in the solicitation to include a drag bag. Of course it had to have the rifle and there was an assortment of ten and twenty round magazines, cleaning kit, sling, scope covers, laser anti-reflection filter, plus spare parts. Basically the whole nine yards.

We knew what that sniper community already had, particularly as far as a kit goes that supports the M24. We emulated with our XM110 candidate as much as we could what they were used to seeing, even to include the M1907 leather sling which has been in the Army for a long time.

Hardigg, in Massachusetts, put a lot of effort into both of the system’s hard side cases. Although the Army solicitation referred to the SASS as ‘Non Developmental,’ there was not a rifle on the planet that met all the criteria they required, much less desired. Likewise with the system case and the second case that fits inside that is used to protect the day scope if and when the sniper needs to take it off.

The scope case had to pass a cold weather drop test at 65 degrees below zero, a drop test from five feet onto a steel plate that was on top of a concrete slab. There was not an ‘NDI’ case that would pass that drop test and also be small enough to also fit in the system case without taking up way too much space. Hardigg really worked hard to make one at minimum size that would pass all these tests.

We submitted our five SASS samples on time in March last year and at that time Reed Knight, the owner of the company, directed that we build another forty more. That was because the solicitation required that if you won and received the award, then you had to quickly deliver fifteen rifles – I believe it was 30 days after award. To get ahead of that curve we went ahead and built forty.

SAR: Give us a quick version of where this program is right now (Feb 2006) as far as Knight’s is concerned.

Lutz: What I’ll call real First Article Testing is being done now up at ATC (Army Test Center, Aberdeen Proving Ground, Maryland) on the fifteen rifles we were required to deliver right after the announcement that we had won. I think really what they’re doing is they’re verifying the barrel life and accuracy and reliability they obviously captured from testing the first five that they used as a selection criteria. About two weeks ago they were at the 3,500 round barrel life point.

Personally, I’m gearing up to deliver training at the end of the month, both operator and maintainer. It’s a contract deliverable that we train their new equipment trainers. So we’ll train them for a week here at Knight’s and I guess they go back to Fort Benning (GA) and practice on each other for a couple of weeks. They also take the handout material and electronic material I give them here and they translate it into the Army boilerplate. Then, they go up to Fort Drum (NY) – probably in May.

SAR: 10th Mountain Division?

Lutz: Yes, they’ll do the Operational Test. Soldiers – snipers – have already tested some of the first five. And also George Niewenhous (ATC) doesn’t have all fifteen of the rifles. Two of the fifteen went to Fort Benning, so the Sniper School has two as we speak.

We know the rifle works and I’ve seen pictures of it being drug thru the mud and through obstacles in part of the testing they did for the first five. It’s been through some hurdles already. But the Operational Test is much more than just testing the rifle. It’s going to test the training program, what they call the ‘POI’ (Program of Instruction) that Fort Benning is going to develop, obviously with some help from us.

They’re going to come up with a way to train the trainers, then take ‘em up to Fort Drum and work with soldiers and armorers who aren’t trained on this particular rifle. The Army will evaluate how effective the training is, the handout material, the amount of hours they need to train on whatever. Does the technical manual adequately show them how to change a gas tube, how to change an extractor? The amount of ammunition; how many rounds are needed for someone to qualify. Those are all parts of an operational test that go beyond whether or not your rifle shoots.

SAR: After that?

Lutz: When that’s finished we expect to get what we call ‘L-Rip’ – Limited Rate Production authorization. By sort of reading between the lines we think that’s going to be somewhere between two hundred and three hundred systems. The first ones are going to end up being delivered in December (2006) because by their schedule December is when the First Unit Equipped is going to be designated. I’ve already heard that the 10th Mountain is real excited about these rifles and they’ve asked permission to take the rifles with them when they deploy.

(Note: Subsequent Army announcements indicate the intent to buy 4,492 systems. SAR has learned that Knight’s is refurbishing the Army’s Operational Test rifles and elements of the 10th Mountain recently deployed to Afghanistan will be the first to receive them as an “urgent need requirement.”)

SAR: Any feedback from the folks who have been testing the XM110 that you can talk about?

Lutz: They apparently have a really good accuracy test stand up at Aberdeen. ATC shoots in a tunnel with no wind, no mirage, no humidity, no mosquitoes biting you like here. The five guns that we sent up for the initial tests all shot under .8 MOA (minute of angle) from the stand.

SAR: Have improvements to the MK 11 in Knight’s XM110 caught the eye of the Navy and Marine Corps?

Lutz: Very soon after the Army selected the SR-25 based XM110, the Marine Corps ordered 180 MK 11s on the current contract we have with the Navy and SOCOM. It’s a MK 11 but they want it with the SASS threaded barrel, the SASS flash suppressor, which also means they get the SASS sound suppressor, and URX type forend, as opposed to the MK 11 forend. And they want it black because they feel it will blend in with the rest of the troops that all have black guns so the snipers won’t stand out so much.

We’ve had joint service meetings where it appears as if the Navy is planning for subsequent MK 11 buys with several of the same things the Marine Corps adopted or wanted, but painted like the Army’s.

SAR: The M110 SASS is semiauto only and has a ‘legal length’ barrel. What plans does Knight’s have to offer the M110 SASS to law enforcement as well as competition shooters in the civilian world?

Lutz: We’ve got our hands full right now with deliveries to the military.

SAR: Any final thoughts on the process?

Lutz: The government would help themselves if they could release some of the specifics as early as possible so we could either develop the things we need to develop, link together those different things that are commercially available, all under one house.

I think the user would have been better served if somehow we would have been allowed to submit the MK 11 Mod 0 – we’ve produced over a thousand of them – as it is. That would have been a true NDI.

(Editor’s Note: Persistent misinformation about the Army’s SASS selection process deserves authoritative rebuttal. The General Accounting Office’s findings on the protest filed by the runner-up system’s proponent may be found at www.gao.gov/decisions/bidpro/297374.pdf)

Visit Knight’s Armament Company on the web at www.knightarmco.comSR-XM110 Rifle System Characteristics Military Description: Knight’s Armament Company’s SR-XM110 is a precision, medium weight, detachable magazine fed, gas operated, semi-automatic, free-floating barrel sniper rifle system, optimized to fire the M118 Long Range ammunition.

Each SR-XM110 SASS delivered contains the following components:

• 7.62x51mm NATO SR-XM110 Rifle
• MIL-STD 1913 Picatinny Rail forend with four rails parallel to the bore with the top rail surface on-line with that of the upper receiver. The design of this forend allows the rifle barrel to be free-floated for enhanced accuracy.
• Back Up Iron Sights front and rear, either integral to the rifle or installed on the MIL-STD 1913 Rail.
• Collapsible Bipod that is adjustable and Operator removable if desired.
• SR-XM110 Magazines: four 20-round magazines and four 10-round magazines.
• Leather Carrying Sling. This sling is also designed to support the rifle in various shooting positions as an aid to marksmanship.
• 3.5×10 Variable Power Day Optic Rifle Scope mounted on a one-piece return to zero MIL-STD 1913 Picatinny Rail scope mount. An Operator removable Laser Filter Unit, Anti-Reflection Device and flip-open dust covers may also be provided.
• A Sound Suppressor that provides very effective acoustic, flash and blast suppression.
• A Flash Suppressor that minimizes muzzle flash when the sound suppressor is not used.
• Protective (hard) Carrying Case for the complete weapon system, as well as a sub-component hard scope carrying case.
• Soft Weapon Carrying Case (aka: Drag Bag. Optional item dependent on individual contract requirements) and a Soft Rifle Scope Carrying Case with padded Scope Cover Insert.
• Cleaning Kit with coated bore rod and guide plus required brushes and jags. Also a pocket-sized field cleaning kit with flexible rod.
• Deployment Kit containing Operator Level tools not provided in the Cleaning Kit, Scope Cleaning Kit, Spare battery for Day Scope Illuminated Reticle, Carrying Case with Field/Operator Spare Parts.
• Operator and Armorer Maintenance Manuals.
• A modified Army M240B 7.62mm Machine Gun Blank Firing Adapter can also be provided.