When one hears the name Knight’s Armament Company (KAC) and/or their president’s name, C. Reed Knight, Jr., one automatically thinks of world class quality and ingenuity. The out of the box thinking has made KAC a defense contractor to be reckoned with; one that is known to supply our most elite special operations forces. The downside is that if you are not military, you waited a long time to get any of KAC’s high end weapons. When the company started out with its development of the renowned SR-25, development was funded through commercial sales. KAC has never mass produced any small arm as attention to detail and strict quality control prohibit this. Every SR-25 that leaves the factory is provided with a test target showing it fired less than 1 MOA prior to it leaving the factory. When news of a new 5.56mm rifle that KAC was introducing was released, it was anticipated that this weapon was going to be in a class all its own. Reed Knight was not just going to come out with a standard black rifle with his name on it – the rifle would be in a class by itself: and we were not disappointed.

As of this writing, the market is awash with black rifles. Nearly every major manufacturer has their own derivative of the black rifle with most M4-type clones with standard features. Relatively few of these weapons are combat grade weapons. Most are made specifically to cater to the commercial market where price is a concern amongst others. However, for those who stand ready to make combat reliable weapons, severe attention to detail, stringent quality control and relentless pursuit of ways to improve the weapon systems are constantly sought. Few manufacturers truly step up to the plate to build combat reliable weapon systems. The cost and facility needed to accomplish such a task are cost prohibitive for many manufacturers.

The SR-15 E3 is very unique in the world of black rifles from muzzle to stock. When designed, the concept was taking the best and making it better. Prior to release, KAC looked at existing weapon systems and looked at the critiques and took them into consideration. They examined the accessories operators were buying to make their weapons more effective and built many of them into their new rifle. With KAC’s involvement with Special Operations soldiers they understood the needs of the operators.

Starting with the barrel, the 16 inch barrel is chrome plated and hammer forged. Many within the SOCOM community feel that hammer forged barrels have longer service life than conventional button cut rifled barrels. They have the Mil-Spec 1/7 inch twist so the barrel will handle any projectile up to 80 grains that could be fed to it. The barrel is free floating in the KAC URX (Upper Receiver Extending) handguard. The URX has quad Mil-Std 1913 rails with a removable lower handguard. The lower handguard is retained by a plunger that is located at the bottom rear of the rail and can be depressed with a bullet tip or suitable tool. The lower handguard is secured (tightened) by two screws, one on each side of the rail. The two screws must be removed before depressing the plunger to remove to lower handguard. There are five integrated sling swivel mounds located on the URX. Two on the front side rails, two on the back side rails and one on the front of the bottom handguard. There are also numerous points that a KAC Sling Swivel Stud Assembly can be installed. Additionally integrated into the URX is a folding front sight. This Integrated Micro-Adjustable Folding Front Sight can be adjusted by hand by a dial. Neither bullet tip nor front sight adjustment tool is needed. The front sight is actuated by pushing inward on a button on the left side of the sight. The front sight post is very unique as well being extremely narrow and round. This is extremely beneficial and will increase accuracy by having a more precise aiming point. The sight is protected by “rabbit ears” to prevent damage. When folded, it has stop notches so optics or accessories can be attached over it.

The SR-15 E3 is provided with a 600 meter adjustable folding rear sight. This is one of the few Back-Up Iron Sights (BUIS) that are adjustable for windage as well as elevation. Of course, any BUIS can be used. Also provided with the rifle for examination was the new line of Micro Sight assemblies. The first is the 600 meter fully adjustable micro sight assembly (KAC part number 25650). This is a smaller and more compact version of the standard one (KAC part number 98474). The other is the 300 meter micro sight assembly (KAC part number 25475). This is a smaller and more compact version of the standard adjustable for windage only (KAC part number 97082). The micro sight assemblies were introduced at the 2009 SHOT Show.

The gas system has been altered from the conventional M4 carbine by utilizing a mid-length gas system. The gas port is placed in between the carbine and rifle gas tube lengths. This gives more dwell time (bolt remains closed longer allowing residual pressure to drop, which allows the cartridge case to contract more before extraction) thus increasing extraction reliability and durability. The URX used on the SR-15 E3 is specifically designed to accommodate the mid-length gas system.

The bolt carrier is a standard M16/M4 carrier with a well staked carrier key. Knights usually fully chrome plates the entire bolt and bolt carrier as their trademark. The SR-15 bolt carrier only had standard chrome plating on the inside of the bolt carrier and carrier key. The outside of the bolt carrier for the SR-15 is the standard Mil-Spec manganese phosphate finish.

The bolt on the other hand is all new. Knight’s were of the mindset to build an improved carbine and to do so would require actual improvements to correct deficiencies. This means the priority is on reliability and durability, not interchangeability. The multi-lug improved E3 bolt is just that. USSOCOM had complained of bolt breakage as the bolts would wear out and more than often they would break at the cam pin slot. Knight’s realized that the only way to increase that strength was to have more material in that area; so that is exactly what they did, by decreasing the diameter of the cam pin allowing more material on the bolt. There is a reduction in the diameter of the firing pin that was the result of creating a solid material recess for the dual extractor springs that astride the firing pin hole. What this adds up to is significant increase in service life of the bolt. Another issue addressed by SOCOM was failures to extract. This was mainly due to worn out extractor springs or lack of use of the newer generation gold springs. The solution was to add a rubber O-ring around the extractor spring assembly. Knight’s took an entire new approach. Rather than band-aid the problem, they created a completely new ejector. The extractor has a “lobster tail” configuration and utilizes two extractor springs instead of one – similar to Karl Lewis’ enhanced bolt. These differ by another major design change by Knights. They moved the location of the extractor pivot pin from the rear quarter to the center. Combine the two extractor springs with the leverage of having the pivot point in the middle you have a major increase in extractor force. A dirt groove was added right behind the extractor claw as well to give dirt a place to go rater than on the extractor claw. Additionally, the locking lug geometry has been changed. The corner edges from the lugs have been rounded off to increase the cross sectional area of the lugs, which increases the strength of the lugs. The bolt lugs are a common failure area of the conventional square lug bolt lugs.

The lower receiver has all been reworked as well. There are and have never been any “stock” weapons to come out of Reed’s factory. Starting at the rear, the LMT SOPMOD stock is used along with a 6-position receiver extension. The stock has a triangular cheek weld along with two removable battery compartments that are water resistant. Also, there are two Integrated Sling Swivel Mounts for the right and left side and a removable rubber buttpad. The lower receiver also has two Integrated Sling Swivel Mounds on the receiver right behind the rear takedown pin. This is a KAC innovation and has not been done in a lower receiver before. These points are preferred by those who like the one-point slings. Moving forward is the KAC ambidextrous selector lever that is not just for south paws as depending on your tactical position you may be holding the rifle in your left hand. Another major innovation by Knight’s is the ambidextrous bolt and magazine catch. The bolt catch is integrated into the lower receiver and is located just above and behind the magazine release button on the right side of the receiver. This enables a right handed shooter to be able to actuate and close the bolt with his trigger finger. Both the magazine and bolt release can be actuated by the trigger finger. The ambidextrous magazine release button is integrated into the lower receiver and is located on the left side right in front of the trigger guard. The ambidextrous magazine release button is easily actuated by the left handed shooters trigger finger. The trigger guard has been redesigned to accommodate a gloved trigger finger and is of Knight’s own design. Like the standard trigger guard, it can be hinged down by depressing the detent. The trigger itself is not stock either and is KAC’s proprietary two-stage trigger. The trigger breaks at 4-1/2 pounds and may be adjusted for as little or more creep and desired.

The sample rifle came with three KAC rail protectors, a vertical pistol grip and one Mil-Spec Okay Industry magazine was provided. That magazine was not stock either and was equipped with a new KAC magazine follower. The follower is identified by its white color and KAC written on the end. This is an anti-tilt follower, which is another reliability enhancement.

The fit and finish of the rifle was superb as what one comes to expect from Reed Knight. It weighed in at a light 6.75 pounds unloaded and measured at 33 inches in length with the stock closed and 36.25 inches with the stock fully extended. The lightweight was extremely surprising considering the enhancements from the basic design. The whole package came in a large black polymer case.

In testing the rifle a few things were added. There was only one thing left this author could think of to enhance the reliability of this rifle even more than KAC already has: that was to feed it with Magpul PMags. Based on this author’s experience, it is the finest magazine made for the black rifle. The PMags with the MagLevel (window) were used. The chosen optic was the Aimpoint CompM4 and 3X magnifier.

The ammunition used in test firing the SR-15 E3 was provided by Silver State Armory (SSA). SSA recently moved into a larger state-of-the-art manufacturing facility in Packwood, Washington. SSA is known for producing high quality match grade tactical and target ammunition and is also one of the few American companies that produce various armor piercing ammunition for law enforcement/military use. The particular ammunition used for this test was 300 rounds of their 5.56mm M193 Ball. This ammunition is actually 5.56mm and loaded in cartridge cases manufactured by Silver State Armory. Accuracy testing was done with Silver State Armory 5.56mm 77gr Sierra OTM (SSAA10075-77Sierra).

When one takes a Knight’s Armament Company weapon to the range, the bar is raised. High expectations are present and when firing the SR-15, there was no disappointment. The rifle was tested on a brisk winter upstate New York afternoon with a chilling 12º F. There were no malfunctions of any kind during testing. In all, more than 500 rounds were fired. The SR-15 shot continuous 1 MOA groups at 100 yards with both Silver State Armory 77 grain OTM and 55 grain FMJ ammunition. The Aimpoint CompM4 with the 3x magnifier worked out extremely well for this distance. Dialing the intensity of the dot down so it did not overpower the size of the bull’s-eye made all the difference. The rifle may serve well as a fighting carbine or a short range containment rifle. It has the reliability and the accuracy to accomplish both tasks.

Knight’s has put out a world class black rifle, one which sets a new standard as to where the black rifle can go and how much more can be done with this timeless design. After more than 40 years this family of weapons continues to evolve. With the talk of a new service weapon it really leads one to ask, “Why?” Properly made black rifles are light, accurate, reliable, user friendly, modular, adaptable and most of all, proven. Knight’s not to long ago was awarded the contract for the U.S. Army M110 sniper rifle system. This moved sniper rifles to another level in the U.S. armed forces. Traditional thinking of having to have a bolt action rifle for it to be accurate had been challenged. The M110 gives every bit of accuracy of the bolt action rifle with the semi-auto firepower allowing up to 50% decrease in engagement time over the current bolt action rifle. KAC is on the cutting edge of black rifle technology and will for sure be a company to follow to see the future of the black rifle.

The industry has seen much change over the last 10 to 15 years in caliber as well as weapon revivals. In the mid 1950s the AR-10 was placed on the Ordnance Corps scrap heap with all the other excellent ideas that were not invented by the Army. The 5.56mm cartridge entered the scene during the Vietnam War and set the course for the next 50+ years. Gene Stoner never gave up on his scrapped AR-10 and then in the early 1990s teamed up with C. Reed Knight Jr. at Knight’s Armament Company and brought back his AR-10 as the SR-25. Unfortunately, Gene Stoner would not live to see his AR-10/SR-25 succeed to equip the most elite units of the U.S. military as well as it being type classified as the M110.

As the debate started in the early 2000s, the direct gas versus piston debate heated leading several companies to introduce piston operated 5.56mm rifles. One of the pioneers was LWRC, Inc. (LWRCI) who was primarily a research and development company. In 2008, essentially all assets of LWRC Inc. were bought by Richard Bernstein whom is well known on the Eastern Shore of Maryland for his many companies which are all defense related. This includes L3’s BAI Aerosystems, and Matech, Inc. LWRCI has had their weapons in the field for refinement and fine-tuning for more than a decade. But that was 5.56mm and 6.8mm SPC. LWRCI has picked up the torch, gone into full fledged manufacturing, and has expanded their line of products to include a 7.62mm rifle that has taken many years to design and refine. Initially the project was spurred by the promise of an open competition by the U.S. Marine Corps for a new semiautomatic sniper rifle, but to date, that has not surfaced.

The REPR (Rapid Engagement Precision Rifle) is a 7.62mm rifle that utilizes the LWRCI short stroke tappet piston system. Like other piston-operated rifles, the REPR uses a free-floating configurable handguard/rail system. One of the common criticisms of piston systems is that the operating rod is attached to the barrel assembly/gas block, which in many designs affects the natural harmonics of the barrel. Now how much that affects accuracy with the REPR will have to be seen at the range. LWRCI’s reason for utilizing the piston system not only revolved around their mantra of a cleaner, cooler more reliable operating system, but they felt it was essential to provide reliability with the shorter barreled versions of the REPR. The barrels can be had in 12-inch (light), 16-inch (light and heavy), 18-inch (heavy) and 20 inches (heavy). Depending on the need, you can have a lightweight carbine, a battle rifle or a sniper rifle configuration.

The REPR system was designed around the needs of a Special Operations Sniper/Assaulter. Sniper/Assaulters deploy with their Special Operations Assaulter teams taking down high value targets be they buildings, encampments or vehicles. Typically the Sniper/Assaulter provides infiltration cover, exfiltration cover and security for the team and target area. To date, the Sniper Assaulters have used either the venerable SR-25 or M110. Most carry a primary weapon as well – typically an M4 or a 10.3-inch barreled MK18 Mod0 5.56mm Carbine. They do this because the M110 and its mounted optic are not ideal for the job of clearing buildings, alleys, and rooms to get to their overwatch position. Sniper rifles usually have long heavy barrels making the system difficult to operate through tight quarters. This is exaggerated when a sound suppressor is in place making the system even longer.

LWRCI envisioned a system that takes advantage of the modularity of the Stoner design. Just push two pins to change the upper, and you have a completely different tool for the job at hand, complete with zeroed optics appropriate for the mission. With the REPR, the Sniper/Assaulter carries one primary weapon, one caliber of ammunition, and does not have to carry two types of magazines. A typical load out might be a 12 inch Assaulter REPR upper with an Aimpoint or EOTech 1X sight. On his back in a courier type tactical case a 20-inch complete with magnified illuminated optics. The 12.7-inch is short enough for CQB, even with a sound suppressor in place and is effective to 400 meters. Once in overwatch position, the upper can be changed out in 20 seconds extending the effective range of the Sniper/Assaulter to 800 meters. The short stroke gas piston allows the uppers to be swapped without changing the buffer or buffer spring ensuring the gun is reliable regardless of what size upper is used. LWRCI claimed they were looking for a rifle that acted like a sniper rifle, but was required to have the durability and reliability of an assault rifle.

One such technology was the adoption of a precision manufactured cold rotary hammer forged barrel. This is a solid departure from most of the other precision semi-auto rifles manufactured in North America. Hammer forging is much more common in Europe, and has not yet been accepted here in anything other than machine guns or assault rifles. Colt Canada (formerly Diemaco) has been using the process since the mid1980s in their C7 and C8 series rifles and carbines. Hammer forging forms the cold metal over a precision mandrel that has the reverse image of the rifling by use of high tonnage rotary hammers. The rifling is imprinted into the bore much like the heads and tails image of a coin is imprinted from a die under high pressure. This work hardens the steel and gives the barrel a much longer service life.

Generally, sniper rifle barrels are unlined precision cut rifled barrels in stainless steel alloy to ensure consistency and precision of the rifling. This provides an accurate barrel, but with one major trade off: life expectancy. A good stainless cut barrel may only last 2,000 rounds before the accuracy degrades. This would not be acceptable for LWRCI’s REPR due to its dual role as a battle rifle. LWRCI knew the major factors in accuracy are consistency of the bore diameter; lack of took marks or chatter in the bore, concentricity of the bore to the outside diameter of the barrel, a perfect crown, clean consistent rifling, concentricity of the chamber to the bore, and lack of structural stresses that might be present in the barrel. Their hammer forging process and finish machining create a very clean barrel devoid of the accuracy robbing problems stated above. Plating the bore with chrome does protect the bore but it is inconsistent in its application, and ruins the work you did to perfect the bore. Instead of plating the barrel with chrome, they developed a process they call NiCorr. NiCorr converts the surface of the material – case hardening it to a depth of 0.005 inch and turning it a lustrous black. They do this inside and out of the barrel. The black finish is from carbon being brought to the surface of the material in the NiCorr process. This same process is used to extend the life and sharpness of metal cutting and machining tools. The barrels are submerged and treated in molten salts followed by a quench and polish process. The temperature of the process is regulated to ensure the case hardening of the barrel while at the same time stress relieving the barrel. Just like heating up a spring until it is no longer springy, the stress relief process prevents the barrel from wanting to shift in one direction when firing the weapon and heating up the barrel. LWRCI claims NiCorr is harder than chrome, has a lower co-efficient of friction, more resistant to heat and does not interfere with the previous work of creating a perfect bore.

Historically the U.S. military would never accept an M16/M4 barrel that was hammer forged even when Colt offered. The U.S. government believes the sharpness of the leading edge of the lands cannot be duplicated in a hammer forge and that the sharp leading edge was critical to accuracy. Some claim the hammer forged barrels last longer and others say the button cut barrel is more accurate. This debate will reconvene for me on the range and be settled one way or another. As there are several technologies present here I have not seen used in combination, I will let the performance of the rifle decide.

LWRCI claims they configured their rifle to meet the requirements of its intended mission and make it as comfortable and ergonomic as possible. They threw out the traditional top rear mounted T shaped charging handle common to Stoner rifles in place of a left side mounted non-reciprocating charging handle with integral forward assist. The reasons cited were three fold. The users required the ability to operate the charging handle without breaking their cheek weld or eyes on target through the optic. If the weapon were to malfunction after a miss, or fail to fire, the valuable seconds required to clear or re-charge the weapon and regain your target in the reticle could be the difference between mission success and failure. They also have a gas shut off on their gas regulator allowing the use of the rifle and charging handle as a straight pull bolt gun. If a sniper was taking a long shot and did not want to leave brass on the battlefield, or when employing subsonic ammunition and a suppressor might prompt its use as a straight pull bolt gun to ensure elimination of any noise from the action. Since Sniper/Assaulters would run the REPR, there is a good chance a sound suppressor would be in use much of the time. The top-charging handle of the Stoner rifles allows a space for gas to escape directly into the shooters face when a suppressor is used. The side charger allowed LWRCI to close off this gap and eliminate AR gas to the eye altogether.

The side charger along with other minor configuration differences took some getting used to, but once it took it was clear LWRCI was on to something. The side charger was easier to manipulate than the standard. Eye relief requirements of powerful optics often cause the optic to overhang the top-charging handle of the M110 making the charging handle difficult to manipulate. LWRCI’s left sided charging handle fixes that annoyance as well. The handle has a forward bolt assist built into it eliminating the right side AR button style forward assist. Pulling back the handle, pressing the handle inward toward the receiver engages the bolt carrier allowing it to be forced forward and closed. The charging handle configuration has also changed the practicality of other operating controls like the bolt catch. Yes, there is still a standard bolt catch in the standard location, but they added another bolt catch to the right side operated by the trigger finger. This makes engaging and releasing the bolt catch very fluid while manipulating the charging handle.

When LWRCI started the REPR project, they went through several iterations; the first being the SABR, or Sniper Assaulter Battle Rifle. They felt the SABR needed to lose some weight, improve in the ergonomics department, and had to be user configurable. They also sought to strengthen and elongate the interface between the barrel and the receiver to limit flex between these assemblies. The stiffer interface would also limit some of the point of impact shift that can occur when a sound suppressor is installed. The threaded front receiver extension was extended almost twice the size that of an AR-10 pattern. They created a new barrel nut that was also very long, and pulled double duty as the handguard/rail mount providing perfect alignment with the receiver. The rail itself is a free float design with a removable top with an integral Mil-Std-1913 rail that is designed to allow access to the piston system and return to zero once reinstalled. The 3, 6, and 9 o’clock rails are user configurable. You only need to install the length of rail you need in a particular location for the accessory you need. This makes the handguard/rail very comfortable, low profile, and cuts unneeded weight.

LWRCI uses an interference fit between the barrel extension and the receiver. Cold, these parts do not fit. To install the barrel, the receiver must first be heated expanding the orifice, the barrel inserted, then it cools and contracts for the interference fit. Under use, this is one of the hottest parts of the weapon, which causes the same expansion. It makes sense to fit these parts while hot. Then they use a lock nut that allows them to put a very precise torque on the barrel. LWRCI felt the current semi-auto sniper rifles were just scaled up AR-15 type rifles with heavy barrels and believes these details have been overlooked when you consider the mission, the accessories, and the user. Getting to some of the mechanics of the rifle, the operating system is made up of the gas block, regulator, piston cup, intermediate rod, operating rod and operating rod spring. The regulator has four positions: an off position making the rifle a single shot, one for suppressed fire, a normal setting and an adverse conditions setting. Disassembly of the operating system is done by removing the top rail of the handguard. Unscrewing the two locking screws located on the face of the end of the handguard and lifting the top rail off is all that is required to accomplish this. With the bolt carrier removed, pull rearward on the intermediate rod and remove the piston cup. Then remove the intermediate rod followed by the operating rod. Simply reverse the process to reassemble the operating system.

LWRC has evolved their 5.56mm bolt carrier over the years and many of those changes were incorporated into their REPR. LWRCI basically scaled up their latest iteration of the 5.56mm bolt carrier group but removed the forward assist notches and added the grooved to the left side of the carrier where the cocking handle will engage. The bolt and carrier are coated with a proprietary Nickel Boron coating that is superior to the previous DuPont Teflon, and Nickel Teflon used. They also coat the barrel extension, the bolt, and the cam pin. Unlike previous 5.56mm iteration carriers, the impact key is not a separate component – it is now machined into the carrier increasing the strength. The bolt carrier also incorporates sand cuts on the running surfaces of the bolt carrier. These simply allow a place for sand and dirt to reside without causing interference to the bolt carrier.

The lower receiver is manufactured from a billet and accepts an SR-25-type detachable box magazine with a capacity of 5, 10 and 20 rounds. KAC, C-Products, Magpul LR20 Mag and DPMS magazines are all compatible for this rifle. The REPR was provided with C-Products 10-round magazines. Acquired for testing were 20-round C-Products magazines as well as the newly introduced Magpul PMag 20LR Mag. The selector lever settings are in the popular pictogram form and have a witness notch on the right side of the selector as well as selector settings on the right side allowing a left handed shooter to know the condition the rifle is in. The stock may either be fixed or retractable. The sample rifle was set up for a sniper rifle and was equipped with the MagPul PRS stock that is adjustable for length as well as cheek weld. The PRS stock is a little on the heavy side but in this authors experience is the finest precision stock for any black rifle. On the heavy barrel sniper variant of the REPR, the PRS’ weight balances the rifle. The lower was also equipped with a Magpul MIAD pistol grip and enhanced trigger guard. LWRCI has teamed with Magpul on all of their weapon systems and use Magpul’s stocks, pistol grips, trigger guards and magazines. The trigger used is manufactured by Geissele Automatics and is adjustable or fixed determined by the model. The sample rifle was equipped with the adjustable trigger that was a two-stage configuration which was very comfortable and smooth to pull. A good trigger is critical on a sniper rifle or any rifle for that matter. Another very innovative feature of the REPR is the ability to tighten the upper receiver so there is no play between the upper and lower receivers. Under the pistol grip is a screw that is tightened by the operator to the desired tension. This ensures a lifetime tight fit regardless to wear on the pushpin holes of the receiver and eliminates the requirement for aftermarket wedge devices.

Both detachable front and rear sights were provided on the sample rifle. The folding front sight attaches directly to the handguard/rail rather than the barrel. It has ears to protect the post and is activated and deactivated by a spring loaded lock. The rear is similar in that it is engaged and disengaged by a spring loaded pin. The rear sight is adjustable for windage only and the front for elevation only. Both sights provided were manufactured by Troy Industries with the LWRCI logo on them.

The cycle of operation of the REPR is as follows: The trigger is pulled releasing the hammer which in turn strikes the firing pin. The firing pin strikes the primer detonating the cartridge sending the bullet down the barrel. Once the bullet reaches the gas port, gas is bled into the regulator. Depending on the setting, the valve regulates the amount of gas that enters the nozzle. The gas chamber/expansion chamber is created between the inside of the nozzle and the piston cup. The piston cup, which is attached to the intermediate rod, pushes rearward on the operating rod which is spring loaded. The operating rod strikes the top of the bolt carrier driving it rearward with a hammer like-blow. As the bolt carrier moves rearward the operating rod spring returns the operating rod, intermediate rod and piston cup back into battery on the gas block. The bolt unlocks and extracts and ejects the fired cartridge case. The buffer/action spring move the bolt carrier group forward stripping a round from the magazine feeding and chambering the round and finally the bolt locks ready for the next shot. Excess gas is bled out of the gas block between the nozzle and the piston cup; therefore no gas enters the bolt carrier group keeping the bolt carrier group clean and cool.

Overall the weapon was extremely impressive. The fit and finish was superb. Every attention to detail was paid and the best choices for the stock and pistol grip were made in my opinion. If this was my rifle these would be the exact accessories I would add. There were no machining scuffs or nicks on the rifle and the anodizing matched on the upper and lower receivers.

Testing was conducted using Silver State Armory (SSA) ammunition. SSA is known for manufacturing some of the highest quality duty and match ammunition in the industry at competitive pricing. Silver State Armory just moved to a state-of-the-art facility in Packwood, Washington where they have a 100 meter underground range and the facility meets United States Department of Defense requirements to manufacture military contract ammunition. They manufacture their own brass. All SSA ammunition is loaded with custom blends of powder geared towards the specific loading. They offer several loadings in 5.56mm, 7.62mm NATO, 6.8SPC and .499 LWRC. They are also one of the only ammunition manufacturers in the United States to manufacture armor piercing rifle ammunition in 5.56mm, 7.62mm NATO and 6.8SPC.

Function testing was done with their 150gr Nosler Accubond cartridge (SSA10084-N150). Approximately 200 rounds were fired for function testing with no malfunctions. Now is the opportunity to see if a hammer forged barrel and a piston have much effect on accuracy in a precision rifle. This load shot consistently just under 1 MOA at 100 yards. For accuracy the Silver State Armory 168gr Sierra OTM was used (SSA10084-OTM). This round consistently shot between 1/2 to 3/4 MOA at 100 yards. The accuracy of the REPR will challenge any bolt action sniper rifle on the market today as well as any other semi-auto out there. The combination of a premium quality barrel, match grade ammunition and an excellent trigger produced respectable groups by any sniper’s standards. Recoil was quite moderate for a semi-auto rifle. Engagement and follow-up shots were quick and accurate, which are the attributes that expand the capability and role of a sniper armed with a semi-auto. I suppose this ends some of the debates I mentioned earlier, however, it is my belief from looking at the multiple design and technology changes LWRCI has made that no one feature is singularly responsible for this performance. It is the proper combination of these design features and technologies working together as a system. This includes the ammunition.

The REPR has undoubtedly added to LWRCI’s opportunities to compete in both the U.S. and international markets on both 5.56mm and 7.62mm rifles. The REPR could be used as a police sniper rifle, competition rifle, military rifle or sporting rifle. It is just that versatile. It comes in carbine and rifle configurations and will serve any need that come up where 7.62mm firepower is needed. The REPR is already in service with the Drug Enforcement Administration F.A.S.T. (Foreign-deployed Advisory and Support Teams) as well as the DEA’s Office of Global Enforcement in Afghanistan and other less than friendly parts of the globe. These are being used in the Sniper/Assaulter role described previously as the teams generally helo insert to a target compound, clear it of bad guys, then take up sniper overwatch security duties while other members of the team or USSOCOM conduct their mission of searching for and destroying drug and weapon caches. The predecessor to the REPR, the SABR are employed by the Pentagon Force Protection Emergency Response teams and can been seen daily in the overwatch positions facing the entrances to the Pentagon. Internationally, LWRCI is has agreed to team with the King Abdullah II Design and Development Bureau to co-manufacture rifles in Jordan for use by the Jordanian Special Forces and Sniper Battalion.

At SHOT Show 2004, a new black rifle was introduced that was not just a copy of the standard design that most of the industry produce. This black rifle would move the family of weapons into new uncharted territory. Karl Lewis, president of Lewis Machine & Tool (LMT) introduced the MRP, the monolithic rail platform.

The MRP is the first monolithic upper receiver. The upper receiver is machined from a single 7075 T6 aircraft aluminum forging. There are four solid Mil-Std 1913 rails and permit complete zero retention for optics or any other accessory placed on the rails. The upper receiver is equipped with a forward assist, fired cartridge case deflector as well as an ejection port dust cover. All rails are numbered for easy replacement of optics to insure they are placed back in the same position from which they were removed. Removable sling swivel mounts are placed on the end of the MRP at the 3, 6 and 12 o’clock positions. Additionally, mounting points are located on the right and left side at the rear of the handguard area by the ejection port. This permits any type of sling or desired location for the operator’s discretion.

The innovation does not stop with the development of the first one piece monolithic rail platform. The barrel, held in by two bolts, is removable by the user. When the bolts are removed the barrel/gas tube assembly is pulled straight out of the receiver. This enables the 5.56mm caliber weapon to be configured for whatever mission it will be used. If a close quarter combat environment is the mission, a 10.5 inch barrel may be used. If the mission is urban or normal combat ranges, a 14.5 or 16 inch barrel may be used. If longer range is required, an 18 or 20 inch barrel may be used. It should be noted the 16 inch 5.56mm barrel uses a mid-length gas system and all others use a standard carbine gas system. All is accomplished at the user level; no armorer is needed to change out the barrels. The barrels are manufactured from machine gun barrel steel and button cut rifling. They are cut with the Mil-Spec 1 turn in 7 inch twist allowing up to 80 grain projectiles to be stabilized. The barrels have chrome plated bore and chambers and are equipped with an A2-style compensator. With Lewis Machine & Tool being a U.S. government contractor for many different parts, they are familiar with what Mil-Spec means and what it takes to achieve it. All barrels manufactured by Lewis Machine & Tool are proof tested with a 70,000 psi proof cartridge and then magnetic particle inspected to insure the barrels are free of stress fractures. When the barrel is installed in the MRP, the barrel is completely free floating. This increases accuracy as well as the air holes in the MRP circulate air to aid in cooling. The removable barrels also enable another innovation: the MRP is a multi-caliber weapon as different caliber barrels can be used. Complete changing of the barrel is accomplished in less than 5 minutes.

The MRP provided for this evaluation came with many enhancements that are all Karl Lewis. Starting with the sights, the rifle was provided with the LMT BUIS (Back Up Iron Sight). This is a fully adjustable rear sight that has been provided to the U.S. Navy and SOCCOM for the MK18 CQB 10.3 inch carbines. The sight is identical to that of the standard M16A2 or M4. The front sight is removable and held on by a nut. It has the traditional triangular shape and square front sight post. Of course, being a Mil-Std 1913 rail, any BUIS can be mounted.

The charging handle has an improved latch that is easier for one to grasp as it is made wider so it is easier to actuate.

The bolt and carrier are also a significant departure from the norm. When Lewis looked at the new design, he looked at the specific operating dynamics of the carbine and how different it is from the rifle. Given the different dynamics, Lewis designed the bolt and carrier to function with that in mind. To begin with, the bolt carrier has had several modifications. Due to the dynamics of the carbine, the bolt unlocks at a faster rate on a carbine length gas system than a full length rifle. Owing to this quicker action, there is still residual pressure in the cartridge case and it is still somewhat expanded when the rifle starts to extract making the extractor and extractor spring work that much harder to extract that cartridge case. It also causes extractor springs to wear quicker than that of the rifle. SOCOM has added rubber O-rings to increase the extractor force to cope with the wear issue. The standard GI M4 has a new and improved extractor spring (copper in color) that is designed specifically for the carbine to increase extractor force. Lewis also redesigned the geometry of the cam track by increasing the dwell time upon unlocking and thus permitting additional time for the residual pressure to drop allowing much easier cartridge extraction. He also added an additional gas relief port to get rid of unneeded gas.

The bolt was also redesigned with durability on mind using proprietary material that is significantly stronger than standard bolt material. Due to its hardness it is more expensive to procure and more expensive to machine than standard bolt steel. The geometry of the locking lugs has been modified as well. There are stress relief cuts that allow more flexing of the lugs to prevent breakage. The extractor has been redesigned as well. The improved “lobster tail” extractor uses two extractor springs instead of one that significantly enhances the reliability of the extractor in adverse conditions. The extractor claw is considerably more aggressive and stronger as well. Like the barrels and as per Mil-Spec, all LMT bolts are proof tested and them magnetic particle inspected.

The lower receiver has many enhancements as well. The stock is the LMT SOPMOD stock and is the stock assembly purchased by USSOCOM and the U.S. Navy for the M4A1 carbines and the MK18 CQB weapons. The stock is triangular in shape and very smooth. There are two removable sling mounting points on the stock as well as a cut-out for a standard GI silent sling. There are two battery compartments that are water resistant tubes placed inside of the stock and there is a removable rubber butt plate as well. The receiver extension is also designed by LMT and has six positions as opposed to the standard M4 which has 4 positions. The provided pistol grip is the Ergo Grip that is extremely comfortable and with the finger grooves is comfortable and makes the rifle stable in the shooting hand in adverse conditions. Also provided on the lower receiver is the Ergo Grip Gapper. This little spacer covers the gap in-between the front of the pistol grip and the trigger guard. LMT’s proprietary ambidextrous selector lever is also provided. This is not just good for left handed shooters but can be just as useful to right handed shooters as well given the tactical situation. Tangodown rail covers were provided on the rails.

The rifle was outfitted with the new EOTech XPS2-2 two dot reticle holographic sight. Extremely compact, this sight uses a single 123 battery and has a battery life is 500 to 600 hours. This sight only requires 2.75 inches of rail space. Along with the sight is the EOTech Generation II 3X magnifier. This comes with a Samson Quickflip tilting mount attached to an A.R.M.S. throw lever mount. When disengaged, the magnifier sits to the right side of the rifle: when engaged for long range shooting it flips back.

Also attached to the rifle was the Insight Tech M3X tactical light with pressure pad activation that was mounted in a Tangodown vertical foregrip. By just removing a spacer, the pressure pad sits in the grip. The grip also is hollow allowing for additional storage.

The magazines chosen for the rifle are the Magpul PMag, one of the finest magazines available anywhere in the world for the Black Rifle. This magazine is a significant reliability enhancement to any member of this family of weapons. The constant curve design allows the shot column to sit in its natural shape and increase feed reliability.

The ammunition for this test was provided by Silver State Armory (SSA). SSA is known for manufacturing some of the highest quality duty and match ammunition in the industry at competitive pricing. Silver State Armory just moved to a state-of-the-art facility in Packwood, Washington where they have a 100 meter underground range and the facility meets United States Department of Defense requirements to manufacture military contract ammunition. They manufacture their own brass. All SSA ammunition is loaded with custom blends of powder geared towards the specific loading. They offer several loadings in 5.56mm, 7.62mm NATO, 6.8SPC and .499 LWRC. They are also one of the only ammunition manufacturers in the United States to manufacture armor piercing rifle ammunition in 5.56mm, 7.62mm NATO and 6.8SPC.

More than 300 rounds of SSA 5.56mm 55gr FMJ rounds were fired through the MRP for function testing and no malfunctions were encountered. There were 200 rounds of SSA 5.56mm 77 grain OTM cartridges fired as well. Groups at 100 yards kept around 1.75 inch groups consistently with the FMJ rounds. All in all, this barrel has had more than 500 rounds through it and as it has broken in the groups had tightened up. First groups fired with the SSA 5.56mm 77 grain OTM were consistent at 1.75 inches. The last groups fired with this ammunition were printing consistently at 1 MOA.

LMT Piston Operated MRP

The industry has gone through a piston craze over the last few years. Although there is no statistical data proving the superiority of piston operation over direct impingement, there has been a market for piston operated weapons in the AR-platform. When asked why LMT began producing piston operated rifles, Karl Lewis simply said “customer demand.” Good enough of an answer.

The versatility of the MRP made it the ideal platform for the piston operated LMT offering. The piston is part of the barrel assembly. The gas block on the barrel has been altered to accept the end cap, piston, operating rod and spring. It is held together as an assembly so the assembly is inserted into the MRP and locked down with the two bolts. The one-piece bolt carrier was modified too for use with the piston. The impact area (key area) of the carrier is machined into the bolt carrier giving strength and durability to the carrier. All the gas relief ports have been eliminated. Skis have been added to the bottom of the rear of the carrier to prevent carrier tilt caused by the off-center movement caused by the impact of the operating rod on the bolt carrier. To remove the piston assembly from the barrel, depress the detent and rotate the end cap and pull outward. Now the operating rod and spring can be removed for maintenance. The piston operated system requires the use of the heavier H2 buffer (two tungsten weights and one steel weight). The MRP piston barrels are offered in both 5.56mm as well as 6.8mm Rem SPC.

Provided for testing was both the 16 inch as well as the 12 inch CQB barrel. More than 300 rounds of Silver State Armory 5.56mm 55gr FMJ ammunition was fired with no malfunctions. More than half of that was fired on fully automatic utilizing a Colt M4 lower receiver. Slightly more recoil and muzzle flip was noticed with the piston operated system

Converting the MRP to Fire 6.8mm Rem SPC

The absolute finest innovation of the MRP is its easy ability to convert to fire a different cartridge. LMT currently makes barrels in 5.56mm and 6.8mm Rem SPC. LMT has also tested calibers in 6.5 Grendal, 5.54x39mm and 7.62x39mm. Provided with the MRP test rifle was the barrel and bolt to convert the rifle to fire the 6.8mm Rem SPC cartridge. The 5.56mm barrel was unbolted and pulled out of the MRP and the 6.8mm barrel put in its place and the bolts torqued down to 140 inch pounds. The bolt was removed from the bolt carrier and replaced with an enhanced bolt chambered for the 6.8mm Rem SPC cartridge. LMT provided four Precision Reflex, Inc. 25-round magazines. Also provided by C Products were five of their steel 25-round magazines.

The first 300 rounds fired were SSA 110 grain Nosler Accu Bond cartridges. No malfunctions were encountered. With this ammunition, the groups at 100 yards remained at 1.25 inches off of a bench. For accuracy, the SSA 115 grain Sierra OTM Match rounds were used. Groups measured at a consistent 1 MOA. Recoil was noticeably more than the 5.56mm but not enough to mention firing on semiautomatic. SSA also manufactures an armor piercing round in 6.8mm Rem SPC. It consists of a pointed carbide core with a machined brass sabot offering an incredible barrier penetration. It penetrates with ease a 1/2-inch thick Mil-A-12560 class 1 armor plate out of a 16 inch barrel at 100 meters at a velocity of 2,800 feet per second.

In research into weapons chambered for the 6.8mm Rem SPC it was noticed there are two different chambers. They are referred to as the spec 1 and type 2 chambers. The spec 1 chamber is the one which has a SAAMI specification and has a .050 freebore. The spec 2 chamber has .100 freebore, which permits longer projectiles (better ballistic coefficient). Additionally, the longer freebore decreases pressure 4-5,000 psi. With a 115 grain projectile, a spec 1 chamber will give 2,425 feet per second and a spec 2 chamber will give a higher 2,575 feet per second. As of this writing a significant number of manufacturers are making their 6.8mm Rem SPC barrels with the spec 2 chamber; however, some remain with the SAAMI spec chamber. This is due to the standardization in chamber drawings. There is a rumor going around that a new chamber specification, which is the spec 2 chamber will be introduced to SAAMI as the 6.8x43mm. As of this writing, only Silver State Armory and one loading in Hornady TAP line is loaded to the spec 2 pressures. Silver State Armory loads both commercial and spec 2 loads. Before shooting spec 2 ammunition in your rifle, consult the rifle manufacturer to determine which chamber your rifle has.

The Lewis Machine and Tool MRP is truly in a category of its own and is the benchmark for the modularity of the M16/M4 weapon system: one receiver, multi-caliber barrels and available in both direct gas as well as piston operated. More caliber offerings are most certainly on the horizon. With all the barrel lengths and calibers offered, the MRP will do just about any job required of it. Whether it is a CQB environment with the 10.5 inch barrel or hunting medium game with the 6.8mm Rem SPC, this one size does fit all. Selective fire versions of the MRP are available to both law enforcement as well as military customers. With the proper tax stamp and compatible state laws, short barreled versions of the MRP can be had by the general shooting community. LMT has been a forerunner in new developments and innovation, which will bring the M16/M4 well into the new decade and beyond.