In this short video, Ian gives a brief overview of Soviet magazines – notably the slab side, ribbed, waffle and bakelite. As always, Ian does a great job and this is worth a watch!
The first generation was a heavily built (over-built) magazine known as the “slab side”.After the slab side, they developed the ribbed magazine that was copied by many countries.To reduce weight they developed the aluminum waffle magazines- so named due to all the reinforcement ribs. It was relatively short-lived because it was not durable enough.After the waffle mag, they moved to the Bakelite magazine that actually was a glass reinforced polymer. This gave them what they wanted – light weight and durability.When the AK-74 was developed, they went straight to polymer and never developed steel mags. Note, other countries did build steel AK-74 magazines but the Soviets did not.
The Video
I hope you found that video useful. Ian is a wealth of information and you can learn more about his work at Forgotten Weapons.
Please note that all images were extracted from the video and are the property of their respective owner.
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While digging for videos on AK magazines, I found this one posted by Apex Gun Parts in 2016. It shows their Croatian AK-47 magazines being manufactured. While they don’t come right out and say they are being made by Zastava, I have a hunch that they are.
I would like you to compare this video to the one I previously posted showing Matra Group’s process. Matra is using older general purpose machines and there isn’t much attention paid to worker ergonomics and lighting.
Now, watch this video and not the differences. This video is showing a much more modern plant where there is also detail provided on their quality control processes and they show the jigs that they use.
The Video
I hope you find the video interesting. Apex Gun Parts is definitely a group that I buy stuff from and have no problems recommending them. I don’t have any experience with these mags so this video is really to let you see the differences in manufacturing.
Please note that all images were extracted from the video and are the property of their respective owner.
If you find this post useful, please either buy something using one of the links in the post or on the following links to eBay and Amazon to buy something. With Amazon, if you click on one of our links and then buy something else – even unrelated stuff like clothes, electronics and groceries – we get credit and it would be hugely appreciated. Doing something like the above will help us fund continued development of the blog.
The AK-47 rifle and it’s “banana” 30 round magazine are classics of rugged functional design. While I’ve posted many videos and how-to articles relating to various rifle and pistol variants, I’ve not really covered the steel magazines at all.
I was surfing around and found Matra Group located in Bosnia-Herzegovina. In 2015 this small manufacturer produced a video showcasing their small facility that makes a variety of steel magazines for AK-47, AK-74 and even Lee-Enfield rifles. The Lee-Enfield may be due to those rifles being supplied to the Yugoslav Partisans in WWII to fight th axis armies.
In the video, they show employees starting with sheet metal and stepping through various steps including stamping, machining and spot welding. For the most part, you will see a very labor intensie process using older general purpose machines. If you like videos that showcase how something is made in and old-school fashion, you will find this very interesting.
Here they are cutting the initial sheet down into usable blanks.Making the front piecee that will lock onto the front trunnion.Spot welding the two body halves together.Gettingg ready for final assembly.
Please note that all images were extracted from the video and are the property of their respective owner.
If you find this post useful, please either buy something using one of the links in the post or on the following links to eBay and Amazon to buy something. With Amazon, if you click on one of our links and then buy something else – even unrelated stuff like clothes, electronics and groceries – we get credit and it would be hugely appreciated. Doing something like the above will help us fund continued development of the blog.
In my previous posts, I covered a bit of the history of the Galil Ace, did two posts about the differences between the Ace and an AKM that I observed (click here for the first and here for the second) and now that leads up to me making a few tweaks of my own to my 7.62×51 Ace pistol.
Moved to a SB Tactical SBA4 Brace
My Ace came with a SB Tactical SOB brace mounted on a proprietary IWI tube with a very heavy hinge. While the SOB is rugged, it is not adjustable so I installed and SB Tactical SBA4 brace.
The SOB4 brace is what comes with GAP51SB pistols. Palmetto had a great deal on this model and that’s why I bought it. If I could have found the pistol model without a brace cheaper, I would have done that.
Now some may wonder why I didn’t just file for a short barreled rifle (SBR) tax stamp and run a normal stock. I may very well do this in the future but I didn’t want to deal with it right now.
The Ace design allows for very easy changing of a rear block by simply driving out one roll pin. The block can the be lifted straight out and whatever you want installed in its place.
The Ace is resting on a green bench block and I used a roll pin punch to tap out that single pin. That’s all you need to do and then the rear plate of the receiver that holds the hinge, or anything else for that matter, will lift right out.With the pin removed, it literally lifts out. Notice how the “plate” or “block” sits in a groove and that’s what provide the bulk of the strength. The roll pin is just stopping vertical travel and is more than enough.
Since the SBA4 is ATF approved, I opted for a modular adapter block from KNS Precision going to an Ace Limited (owned by Doublestar and not IWI) folding M4 adapter – the FSM-AR. Note, if you install a folder, buy one with the boss – the raised oval shape. It will fit into the groove in the KNS Precision adapter and make for a very solid connection.
This is the external face of the KNS Precision adapter. The groove is where the boss from the FSM-AR adapter will sit to limit movement. I’d recommend always getting adapters with the bosses unless you intentionally do not want them. The two screw holes allow for variations in mounting.This is the back side of the KNS adapter. The one roll pin goes through one of the grooves to hold it in place. It is very nicely done – kudos to KNS Precision.The KNS adapter just slides right in and is secured by the roll pin.This is the Ace Limited (owned by Doublestar and not IWI) FSM-AR adapter. You can see the oval boss on the left part of the folder. This gets flipped over and screwed into the KNS adapter. Also, oil the hinge at some point before you close it. Sometimes they can be a bear to actuate when dry — personal experience talking there. Also, use blue Loctite on all screws or they will shoot loose.
Special note – the charging handle for my Ace pistol is on the left side. In my case, I was not worried about operating when folded. If you want to fire with the stock folded, you must go with a right side folding mechanism. If I had it to do over, I would have used a right-side folder but I simply used what I had in this case to cut cost plus I don’t plan on folding it much.
Here’s the Ace folder open to the left and the brace assembly does interfere with the charging handle. If you want a weapon that will operate with the brace folded, then go with a unit that folds to the right.
The SBA4 comes with a Mil-Spec receiver extension (buffer tube) and I used a generic castle nut that I had in my tool box along with an end plate that has hoops to connect a sling.
The SBA4 comes with a Mil-Spec receiver extension/buffer tube. You will need to supply your own castle nut .
I only use my Magpul wrench now for installing castle nuts as it enables a very positive/sure connection. I’ve done my fair share of scratching stuff with tools that used older methods and the MagPul is the way to go. I also used an automatic center punch to stake the nut.
For dealing with castle nuts, you simply can’t beat the Magpul wrench. I don’t use the combo wrench below it any more because I have scratched a ton of tubes accidentally with it.
All in all, it was a very straight forward swap and allows for some adjustment now. In case you are wondering, the SBA4 is very beefy. I do not like the SBA3 as the end is soft and and ears that go around the shooter’s forearm just kind of bend and flop around. The SBA4 is very well done.
I definitely will SBR it at some point down the road but am happy with what I have for now.
Installed a RS Regulate GAR-9M-N Handguard
I was not fond of the original handguards and was pretty sure I would like the GAR-9M-N handguard from RS Regulate based on photos that Scot Hoskinson had posted. Let me tell you, it is a huge improvement. First off, it’s way longer and second it uses a M-LOK attachment method for accessories so you don’t have unnecessary rails bulking up the girth like you do with the originals.
This is the RS Regulate GAR-9M-N handguard for Ace pistols. It’s machining and finish are excellent. Installation was very easy.
Scot Hoskinson, the owner of RS Regulate, has put together a real nice installation guide with plenty of illustrations. The one thing I’ll tell you is that the two original handguard screws from IWI have threadlocker on them.
Just behind the mouth of the gas tube & front sight block is the mounting point that holds the two screws that retain the original Ace handguards. They do have threadlocker on them so warm them up to make removal easier.I used a 1/4″ ratchet with a 4mm allen bit and the retaining screw on each side came right out. Note, you will see two rivets on each side – one rivet head is visible between the wrench handle and the bit. You don’t need to do anything to those. You just need to remove the two screws. You can see one of the above just forward of the bit.
You can heat them up and make them easier to loosen, use a 1/4″ ratchet with a 4mm allen/hex head to break the screws free or, what I did, was a bit of both. With the gas tube off and out of the way, you can see where the two screws mount on the barrel. I heated that up and backed them out with the ratchet pretty easily.
Once the screws are removed, slide the handguard forward slightly and pull the rear down. It will come right off.
From there, you basically pull the stock handguard down nose first and pull forward. Then, follow Scot’s instructions. You will need to pay attention and install a small spacer between the barrel mounting point and the handguard when you install the new screws. I applied blue Loc-tite and torqued them down to 25 in/lbs per Scot’s instructions. You also have to install one long screw at the rear that you’ll want to use the blue Loc-tite and torque to 25 in/lbs also.
The RS!Regulate comes with the three screws, two spacers and an allen wrench. I applied medium-strenght Blue Loctite and used my Vortex Optics torque driver to tighten the screws to 25 in/lbs. The installation instructions where spot on and I did not encounter any surprises at all. The unit bolted right up with no fitting needed.The fitment is really superb. Here the rail is sliding over the rear block and will be secured later with the long screw that squeezes the rail’s walls together further locking it in place.I like the RS!Regulate unit far, far more than the original. It’s longer and it fits my hand way better in terms of girth.
Opted For a Vortex Razor AMG UH-1 Optic and 3x Magnifier
I figure this will be a close in weapon – certainly within 200 yards probably – and will figure that out when I get it to the range. With that in mind, putting a high power optic on it just does not make a lot of sense but I also wanted magnification just in case so I checked out what Vortex Optics had to offer.
I’ve now used a boat load of their red dots and scopes on all kinds of firearms including 12 gauges, .50 Beowulf and .338 Lapua. They’re solidly built, good glass and back by a no-nonsense warranty. So they are my go-to for optics and have been for several years. Yes, I do actually have to buy them and no, they do not pay me to say that.
At any rate, I’d been eyeing the Razor AMG UH-1 for a while. Now that is a mouthful and I notice a lot of guys just refer to it has the “Huey” due to the UH-1 helicopter. It’s a true holographic sight which means a laser image (a hologram) is projected into the viewing window. The benefit of this is that regardless of the angle you look through the lens at, if the dot is on the target, it’s going to hit there.
The Razor AMG UH-1 or “Huey” mounts easily with its quick release lever and is ruggedly built.It has a large viewing window that makes sight acquisition very fast.The controls are well laid out and easy to use.
Battery life is somewhere around 1,500 hours and there are a lot of variables that can influence that including the brightness of the reticle (there are 14 levels), whether you are using a CR123A battery or a rechargeable LFP123A. Note, Vortex found that recoil kills the basic rechargable RCR123 batteries in 2-300 rounds. They stopped testing the LFP123A at 10,000 rounds and it was still working. I’m using the supplied CR123A still at this point and will likely use Surefire CR123A batteries going forward as I keep them in stock for lights.
In short, the Huey is very slick and it’s getting great reviews. I’ve been a long-time red dot fan and the UH-1 is my favorite at this point.
To get a better view at 100-200 yards, what I did was to pair the Huey sight with the Vortex V3XM Micro 3x magnifier. What this does is give me the ability to install, remove or even swing the installed optic out of the way when I need or don’t need the target to be magnified 3x.
Some assembly was required and I applied medium-strength Blue Loctite to the screws.Here’s the Vortex Micro 3x magnifier paired with the Huey.
The V3XM is small, light, has a quick release lever also, just like the Huey, and pairs very nicely with it.
Here’s the end result with the SBA4 brace, RS!Regulate rail and Vortex Optics combo.
Summary
The pistol really turned out slick. It balances well and ought to be a blast. Now just to find some time to get to the range before it really gets cold 🙂 Here are some photos for you:
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AK handguards have evolved from wood to bakelite to elaborate affairs made of polymers or aluminum. In the case of the Ace, no rhyme intended, an aluminum handguard with Picatinny rail is covered by sculpted rail covers.
The handguard is U-shaped with rails at the the 3-, 6- and 9-O’clock positions. The top rail is integral with the gas tube. Note now they have a cut out read for a pressure switch and the rails are open on the middle for wiring. There is one socket screw on each slide to fasten the handguard to the weapon.The two socket screws thread into a retainer and have thread locker on them. When you look at the top of the rail, you see a small circle indentation on each side and then just a bit further back a rectangular shaped indentation. The screws are on each side. Also, you also get a good view of the front sight .These are the three rail covers for the handguard. They lock into place and can be released by pushing the visible button at the back. The panel in the middle is the bottom piece and it has a lip that serves to help you index your hand.
So, two differences to note – a unique railed handguard and it is held in position with screws vs. the traditional AK front handguard retainer.
As a personal comment, I stopped buying tri-railed handguards some time ago because they feel too fat for me once you add on rail covers. The Ace handguards aren’t too terrible but they are fat and shorter than I would like. The stock unit will be replaced by one of the excellent handguards from RS!Regulate – the GAR-9M-N model to be exact and that will be in a future post.
The Gas tube has tabs and a rail but no lever
This is a unique little item right here. The gas tube slides into place via tabs on the unit that mate with slots on the rear base. It does not have a locking lever like an AK does.
The top has a Picatinny rail and the whole unit is locked into place when the dust cover is installed, which pushes the gas tube forward into position. The fitment is so well done that the Picatinny rail is level all the way across the top.
The gas tube goes over the nipple on the front sight block. The relieved tube you see with the screws are where the handguard retainer screws thread in from each side.This is the gas tube with the rail on top. Note the tabs at the bottom rear and the groove on the rail that mates with the rail from the dust cover.Here’s another angle – you can see the heat shield on the handguard and the slots on the rear block. We can’t call it a Rear Sight Block (RSB) like we would on an AK because the sight is on the dust cover on the Ace. Here, all it is doing is securing the gas tube.The fitment of the dust cover and the gas tube are so well done that despite being two separate parts, their two respective rail sections align very nicely.
Integral lower plastic assembly – grip, magazine guide
Part of the revisions from the IMI Galil to the IWI Ace was changing 12 parts from steel to plastic. To be honest, I did not hunt down all 12 and itemize each. What I did readily see was the plastic lower assembly that connects with the steel forged receiver. It has the following:
An integral grip that has a hollow storage area
Ambidextrous magazine releases
An enlarged integral trigger guard
A natural hand hold curve just forward of the magazine
Folding Brace Assembly
IWI makes two models of the 7.62×51 pistol – the GAP51 without a brace and the GAP51SB with the brace. I really just needed the GAP51 but went with the GAP51SB because the price was so good from Palmetto State Armory at the time.
What you get with the GAP51SB is an IWI designed integral folder with a 1.25″ diameter pistol tube and an SB Tactical SOB brace. The SOB part makes me smile every time I write it. So, it does give you a well designed fixed length brace and a rock solid folder.
The SB Tactical SOB Brace with the unit locked into position.That hinge is soooooo cool.A close up with the brace folded alongside the receiver.The unit is very compact and functional with the brace closed. Note the IWI logo on the brace but it is definitely an SB unit and the butt end has their logow. SB Tactical OEMs for others as well – meaning they will sell units with the logos of other firms displayed.
Magpul Pmags
No AK ever used Magpul magazines so I think this counts as a difference 🙂 The 7.62×51 Ace uses Magpul’s 7.62×51 PMags. You can get them in a number of sizes as well as a drum if you really want to rock and roll. I bought some 20s, 25s and one of the D50 drums. I’ve not tested the pistol yet but expect it will work great with all of them.
The 7.62×51 Ace uses readily available Magpul Pmags.
The Manual
I can’t say that I’ve ever read a very good AK manual that has tons of illustrations and covers a lot of topics – operating, cleaning, trouble shooting, and a detailed parts breakdown. The IWI Ace manual really is exceptional. The PDF copy is 88 pages long!
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The Ace is definitely a modernized AK weapon. One look inside confirms that. The Colombian defense firm ofIndustria Militar (INDUMIL) began a commercial relationship with Israeli Military Industries (IMI) that would later carve out the small arms division to become Israeli Weapons Industries (IWI). Their collaboration was on the Galil Automatic Rifle (AR) and INDUMIL obtained exclusive rights to it.
What the two organizations accomplished is remarkable. The two collaborated and modified 43 of the 96 parts in a base Galil AR to reduce the weight by approximately 1 KG (about 2.2 pounds). 12 of the parts shifted from steel to plastic. The goal wasn’t just to reduce weight, they improved precision as well.
I decided to see how many differences I could observe between it and a traditional AK. I wish I knew enough about Galil’s to compare a traditional Galil AR to the Ace but being an AK guy, I was very curious to see how the Ace compared.
I tried to be objective about things and started out that way but the more I took the pistol apart, the more genuinely impressed I became. So, let me try and catalog the differences with as many photos as I can.
Two Chamber Muzzle Brake
One thing that caught my eye was the two chamber muzzle brake and that it is held on by a jam nut, which is a nut that is tightened uo from the rear against the brake to lock it in place. The thread is 5/8-24 for the 7.62×51 Ace models.
In comparison, an AK-47 typically has a 14mm diameter by 1mm pitch left hand thread (14x1mm LH). They are held in place by a detent pin that protrudes from the front sight block (FSB) and engages a timing groove that secures the brake in the correct orientation. Now, 14×1 LH is typical for AK-47s but once you add in the variants, threads are all over the place with different style brakes and boosters.
Improved Sights
Note the longer sight radius, integral gas block with front sight, aperatrue rear and protected front sight.
There are five things I noticed right away
The Ace has a longer sight radius, which is a fancy term meaning the distance from the rear to the front sight is longer. In general, the longer the sight radius, the more accurately the weapon can be aimed.
Aperture rear sight – The Ace sports an aperture (meaning a hole you look through) rear sight that has flips to show either a small circular hole for distance work (300-500 meters) or a larger circular hole for close quarters work (0 to 300 meters).
Integral Front Sight and Gas Block – The Ace sports a combination gas block that combines the gas and front sight blocks. Note, AK folks use the term “blocks” to refer to the three sub-assemblies that sit on the top of the barrel – the front sight block (FSB), gas block (GB) and rear sight block (RSB).
Both the front sight post and the larger rear aperture have Beta Lights – Tritium Gas – for low-light visibility. In general, tritium is radioactive and will last about 10 years. After that, the sights still work but you will not have the glowing effect.
The height of sights enables co-witnessing with optics such as red dots.
View of the front sight and you can see the tritium (white dot) painted on the post.Rear sight with the close quarters aperture flipped up. Note the tritium circles for low light. This close quarter aperture is 0-300 meters.View of the rear sight showing the smaller aperture sight flipped down. It is used for distance work and the manual identifies it as 300-500 meters.
Ok, this pistol is in 7.62×51 and has an 11.8″ barrel – I’m real curious to see what it can do within 100 yards. The sights are the same used on the full size 16.5″ barreled rifle so I really don’t think the smaller aperture would ever realistically be needed but we will see.
Railed Dust Cover
The dust cover of the Ace is pretty interesting. Most of the cheap aftermarket railed AK dust covers simply aren’t very stable or consistent when the dust cover is removed, installed and the weapon fired – in short, they don’t really work very well.
The Ace dust cover is beefy and installs very firmly with no travel it is a stable platform to build on. The top of the dust cover has a Picatinny rail section on the top that is welded in place. It aligns with the rail section on the gas tube via a small tab.
This tab slides into a corresponding groove on the gas tube to align the two rail sections,
The rear of the dust cover has a second layer of sheet metal wrapping the bottom making for snug fit and reducing flexion.
This is the dust cover = you can see the rail, dual aperature rear sight and the double reinforced rear bottom that mates with receiver.You can see the welds that secure the rail to the dust cover plus the reinforced rear.
In short, the dust cover is remarkably solid. I actually have to give it a knife hand chop on the rear to get it to seat down fully into the receiver. It needs to fit tight as the installation of the dust cover also locks the gas tube in place.
Milled Receiver
Speaking of the Ace’s receiver, it’s milled and built like a tank. I found it very well machined with nice touches like a funnel design to help guide the recoil rod assembly into position.
As an example of the care taken in the design, note how the seat for the operating rod assembly is funnel shaped to help with installation.
Note, while the modern AK (AKM ) uses a stamped receiver, the Type 2 and Type 3 AK-47s used milled receivers so it’s not entirely new but it does differ from the AKM. In fact, some countries continued to use milled receivers such as Bulgaria, Finland and Israel in at least some of their weapons.
Milled Recoil Assembly With Rubber Seal
The recoil rod and spring assembly is of a tubular style you typically see in RPKs. The benefit of this is a more consistent pressure being applied to the bolt carrier particularly when it comes to lock up. The thumb tab that locks the dust cover in place seems a tad longer than what I see in other AKs. Last comment is that they added a rubber seal at the rear of the assembly to seal out debris.
Here’s the recoil rod assembly with the dust cover removed. You can see the long thumb tab and also the rubber seal. It also gives you a good view of the plat that seals the length of the groove where the bolt cocking lever passesShows the recoil spring, tubular rear, round front shaft and retainer. In an AKM, rather than a tube and rod, two pieces of folded wire form the central element and can bounce all over the place. Not a big deal in a typical AK but it does matter when you want to improve consistency.
Forged Galatz Fire Control Group (FCG)
The Ace FCG is very nice. Let’s face it, most AK FCGs reflect and elegantly utilitarian design that isn’t very refined. I have always been impressed by the simplicity of the AK design and what the Ace designers decided to do was to take the enhanced FCG from the IWI Galatz designated marksman’s rifle (DMR) and used it in the Ace weapons.
Here are some differences I noted:
A single large forged trigger hook for holding the hammer
Engagement surfaces are polished such as where the disconnector grabs the hammer
Hammer and trigger springs are separate whereas the AK has two wires spiral wound together that power the hammer and push down the rear of the trigger’s rear ears/bars.
The top of the hammer is asymmetrical with only half of the normal bar that adds mass to the top rear of AK hammers. This is what normally gives an AK hammer the hammer-head shark hook.
View of the hammer. Note the polishing. You can see the double-wound hammer spring and a part of the single-wound trigger spring sitting on the left ear of the trigger.Here it is from another angle. You can see the top rear of the hammer is asymmetrical vs. having the hammer-head shark design typically found in AK rifles.
An AK has a single selector lever on the right side of the rifle that also serves to seal the receiver. It’s about as basic as you can get. On a semi-auto AK, the selector either physically blocks the trigger from actuating by moving a bar directly above the rear ears of the trigger or it moves out of the way allowing the trigger to move freely. On an automatic weapon it also allows the user to select full-auto or semi-automatic.
The Ace has a thumb control on the left side and more of a switch vs. the traditional long lever on the right side. Internally, the linkages do the same thing for semi-automatic in terms of moving the block bar into or out of position. The Ace has a separate plate for sealing the groove where the cocking handle reciprocates so the selector lever is not doing double-duty in that regard.
Visible are the thumb selector switch at to top of the grip and so is the charging handle and the very interesting articulating plate that pivots down and allows the charging knob to pass by in both directions.Here’s the right side selector switch located where the traditional long AK selector lever would have been.
Note, the thumb selector connects to the safety bar via a linkage. The movement of the lever is an arc and not a horizontal slider. It is stiff and definitely needs lubrication when you get the weapon. I’ll comment more about that below when reviewing the pistol grip base.
Pistol Grip Base vs. Grip Nut
With AK’s, there tends to be a grip nut or in the case of Yugo-patterned AKs, a grip strap with an integral nut that the grip screw threads into. For the Ace, there is a “pistol grip base” that is uniquely shaped because it has a tube on top and my best guess is that it is to limit travel of the thumb selector and possibly to trap the pin so it can’t back out if it were ever to come loose.
The “barrel” in the middle of the receiver is the top of the “pistol grip base” as IWI terms it in the manual. You can also see the linkage – you’ll definitely want to oil this.Another angle on the grip nut and thumb selector linkage.Just behind the selector bar you can see a 6mm thread protruding from the bottom of the receiver. It is threaded into the unique “pistol grip base”.
Bolt Carrier and Bolt
The moment you open up a Galil Ace, you know you are looking at a rifle with an AK heritage and the bolt system clearly is AK inspired. When you look at the bolt and carrier, the refinements are interesting:
Most obvious perhaps, the traditional right-hand side cocking left on the bolt carrier has been moved to the left side and is tubular to reduce mass.
The bolt carrier has a lightening cut – that would lower mass and impact energy
Bolt and carrier do not appear to have serial numbers. While I can’t find confirmation of what I am about to say, perhaps the manufacturing tolernces are so good that the traditional hand fitting and matched components are no longer required.
At least for the 7.62×51 version the gas pistol is significantly shorter and has a collar on it.
While an AK’s firing pin is free floating, the Ace has a spring loaded firing pin that is pushing it back away from the bolt face. Now some will argue whether this was really needed or not but it is a design difference.
Note the short piston with the collar and that the cocking tube in on the left side.A better view of the very short gas pistonHere’s a view of the underside of the carrier with the bolt installed. Note the knurling on the kocking lever. I am curious about the pin hole under the cocking tube. It may allow for the swapping out of the lever – some dayI will take it apart and see if this is the actual case.Here’s the bolt. Definitely a good sized extractor.Lightening relief/cut on the carrier.Bottom of the carrier with the bolt removed. Curiously, notice the machining marks where the bolt’s lug would engage with the carrier.
Wrapping Up The First Post
There’s definitely more ground to cover and that will be in the next post. Click here to read it.
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I had a fellow who was new to AK-47s/AKMs ask me the other day how the two pins work and if there was a published specification for them because his were floating in their holes. I learned a long time ago to try and help guys learn so I took a few photos and sent them to him.
Two Pins for Semi-Auto AKs
In a fully automatic AK, there are three pins and they are referred to collectively as the fire control group (FCG) pins – this includes the hammer pin, trigger pin, and sear pin – once in a while you’ll see the word “axis” thrown in there somewhere. For most civilians, we’ll just see semi-auto AKs so there are just two pins – one for the hammer and one for the trigger assembly which is made up of the trigger and disconnector. They are still called the FCG pins.
For anyone that is interested, a 1968 Soviet era armorer’s manual does have the pin specification:
This is from a Soviet era Armorer’s Guide that specs out the AKM fire control group pin. The shaft is 5mm and is where the trigger and hammer rotate. The same type of pin is used for both the trigger and the hammer – they are not unique.Here is a pile of pins from a mix of countries. I had them in one of my parts boxes. The diameters of the shafts vary from 4.921 to 4.988mm according to my micrometer. Based on the armorer diagram above, a diameter under 4.97 or over 5.03mm is out of spec. Three of those pins were under 4.97 interestingly enough.
Odds are that the heat treat is messed up on his receiver or someone drilled the holes out of spec. He has enough info now to decide his next steps and since I wrote most of this already, I decided to post it in case it helps someone else.
Accessing the 1968 AKM Armorer’s Manual
I am going to try hosting his huge armorer’s manual PDF file and see how it goes. If people have problems downloading it, I’ll just remove the link – click here for the 64MB PDF file. Note, I am not the owner or creator of that file. Someone did us a huge favor by taking the time to scan in all the pages and share it. It is in Russian and has a ton of diagrams.
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A few years ago, I bought a 1969 Polish Radom Circle 11 AKM kit from Arms of America. It has laminate furniture, matching parts and they populated a new Polish Chrome Hammer Forged (CHF) barrel with the front, gas and rear sight blocks. Furthermore, it was headspaced. I double checked that before I pushed out the barrel pin and then the barrel – that’s where things got interesting.
Pressing Out The Barrel
I have a 30 ton H-style hydraulic press with a 20 ton air-over-hydraulic bottle. The thing is a brute and have used it many, many times over the years on gun and car projects. There are a few things you learn over the years – 20 tons is 40,000 pounds and is a serious amount of pressure – steel parts can bend, break or even shatter under those loads. You learn to go slow, watch carefully feel the pump and listen. I also learned long ago to use the air to move the ram quickly but always do the real work by hand for those very reasons – I’ve bent the crap out of stuff in years past because you can’t tell what is going on.
I wear a full face shield when working with a press. I’m not joking when I say things can go bad fast when there is a lot of pressure. When you push out a barrel, you just don’t expect a ton of pressure from a new kit – at least I don’t. I’ve had some real hairy barrel pins and barrels in years past when dealing with surplus… but not on a new kit with a populated barrel … not until now.
Pressing Out the Barrel
As you can guess, the barrel did not press out easily. I had to apply a boatload pressure – way more than average. So much that I put a 3/4″ piece of plywood between me and the trunnion/barrel assembly. I was also checking and double-checking that my barrel press tool squarely on just the barrel and not a part of the trunnion – guys I was nervous.
I reached the point where I knew I was squarely on the barrel and something had to give. I was whacking on the press trying to shock the barrel out and I kept upping the pressure – pump, whack, pump, whack… Finally the barrel came free like a gun shot. Guys- do you remember the old Romy kits where the pins and barrels sometimes felt like you were taking your life into your own hands? That’s what this felt like.
I actually inspected the front trunnion very carefully looking for cracks. I then inspected the chamber end of the barrel – nice and smooth – remarkably smooth. No signs of galling. Ditto on the inside of the trunnion. I suspect that someone was using some kind of press system that included a barrel support and slammed that new barrel in using a level of force I couldn’t do without damaging parts. I noted to myself that reassembly was probably going to be just as colorful.
Building The Kit
Nothing new about building the kit – I had fun. In the below photo, the front trunnion and rivets are just sitting there. I was mocking things up and they are not actually set. I installed the trigger guard taking care to orient the selector stop properly and using a rubber band to keep the assembly together as I used my press and an AK-Builder trigger guard rivet jig to do the job.
The rubber band keeps the receiver down on the trigger guard jig so the rivet, selector stop and trigger guard all stay in place while you move around. The AK-Builder jig really does a nice job.Here, everything is drilled and seems good to go.
So let’s get back to the main point of this blog post and why you are probably reading this – what do you do when the interference fit is too tight and the barrel will not go into the trunnion all the way.
Life Got Colorful Trying to Press The Barrel Back In
Yeah, that tight fit came back to haunt me. I tried polishing the trunnion and applying non-seize. Usually this works for me but when I went to press the barrel back in, it would not go. I saw the barrel begin to deflect in the press and immediately stopped. Let me explain what I mean by deflect – a material will bend so much and spring back into place. When I saw the barrel begin to deflect, I immediately stopped – it was taking way too much pressure and I was risking bending the barrel permanently. It was time to press the barrel back out and rethink the situation.
Here’s my barrel and my receiver. I double-checked the barrel to make sure I did not bend it – I got lucky. I always get worried if I see the barrel start to deflect/bend — they don’t always return to true.
So, what this confirmed for me was the someone slammed this thing together – hard. An AK barrel is press fit into the trunnion. To do this, the barrel is a tad bigger than the hole made for it in the trunnion by about 0.0010-.0026″ (0 .025-0.065mm) according to Robert Forbus who is a true machinist and has shared a ton with the AK community – click here for his page). At the tighter end (around 0.002″) it is getting hard, if not outright impossible, for someone to press the barrel into the front trunnion without the proper specialized barrel press equipment that supports the barrel. I have a big press but nothing to properly support the barrel in these high-pressure situations. It would likely warp like a wet noodle if I just kept adding pressure.
I don’t own a machine shop but I am a redneck with a shop. I needed to open up the barrel channel in the trunnion and opted to use an OEM brand brake hone. Why? Because I’ve used these small bore hones in the past for other things and was pretty sure it would work for this too.
I also need to point out that I have no way to accurately measure the barrel or the trunnion so I figured I would remove a bit and try to install the barrel, remove a bit and try, over and over until it went in. The next picture shows my OEM hone (and the Lisle is virtually identical):
This is an OEM Tool brand brake hone and the Lisle unit looks virtually identical.
Take a look at the above picture – by tightening the knurled nut at the base of the spring, you can apply more and more pressure to the 220-grit stones at the end of the arms. (The Lisle tool’s stones are 240 grit purely FYI – not a big difference.) I just used the basic pressure and did not increase it. Life lesson for me years ago – it’s easier to take more material off than it is to put it back on.
I applied cutting oil to the trunnion liberally and then slid the hone in and out with my drill on slow speed. I would do this for a bit, clean stuff, and then tested how far the barrel goes into the trunnion by hand and then keep removing more. This is not the time or place to get impatient.
By the way, OEM makes fine 400 grit stones that you can swap into place and use to polish the interior further if you . I got the job done with the 220 grit stones and silver Permatex anti-seize compound. If I ad the 400 grit stones handy at the time, I would have done so but I did not. Also, be sure to clean out the grit/dust before you try to reinsert your barrel.
My one action photo and it was blurry! You get the idea. Keep it lubed with the cutting oil and keep moving the unit in and out so you are polishing the whole barrel channel.
This is a down and dirty “git ‘er done” approach and will make machinists cringe. I go slow and test — I would push the barrel in, test and the press it back out if need be. [Click here to see how to make a barrel backout tool].
*IF* you see a bur or squished rivet protruding in the trunnion, then carefully grind that down with a Dremel and polish with the hone. Don’t try to do it all with the hone or you will be removing material elsewhere that you may need – the arms are spring loaded and independent so they will go where ever they can. This is a pro and con.
After a couple of tries, the barrel went all the way in with the press. To be safe, I confirmed the head space using real Manson brand 7.62×39 gages (use real gages folks and treat them well – don’t go cheap). The barrel headspaced just fine so I pressed in the pin and finished the rifle up.
Bottom line, a brake hone can help you carefully remove steel from the front trunnion and get a tight fitting barrel to go in. It worked wonders on this 1969 cold warrior that is now ready to go to the range.
The 1969 Polish AKM rebuilt and ready for the range!The rifle is wearing one of our Polish Tantal/AKM grips as a 922r compliance part – we make them by hand here in Michigan from a glass fiber reinforced polymer.
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Guys, I must confess that I have a coffee addiction 🙂 As most of you know, I am into AK rifles as well. As part of that interest, I have read every biography I could find of Mikhail Timofeyevich Kalashnikov to try and better understand what led to the creation of the AK-47 and the eventual family of Kalashnikov designs.
Recently I was searching on Amazon and surprisingly found a coffee cup with a great photo of a young Kalashnikov that was tastefully done and, of courcase, had to order it. I had to wait a few weeks as it shipped from Germany.
When it arrived, I was surprised that the graphic was a different color than what the Amazon ad depicted. I thought about returning it but I do like the cup. The following shows you the cup that arrived – it is pretty cool and the color has grown on me.
My wife’s reaction was “Why did you buy another coffee cup?” To which I answered “But honey, this is Kalashnikov” at which she just turned around while shaking her head 🙂
In case you are looking for a conversation piece, check out this cup. Here’s the listing on Amazon.
7/3/2019 Update: It’s holding up just fine. It does make for a cool conversation piece when people use it. “Who is this guy?” is usually how it starts 🙂
If you find this post useful, please either buy something using one of the links to eBay and Amazon. With Amazon, if you click on one of our links and then buy something else – even unrelated stuff like clothes, electronics and groceries – we get credit and it would be hugely appreciated. Doing something like the above will help us fund continued development of the blog.
I am really enjoying these videos that Kalashnikov Concern in Russia is producing. In this video, Vladimir Onokoy, a technical consultant with the Kalashnikov and experienced AK armorer, discusses the Hungarian AK evolution with Pavel Pticin, founder of the AK-info.ru web portal, who has extensive AK knowledge.
I’ve always liked Hungarian AKs and found them to be high quality. Over the years I’ve built several AMD-65s and an AMMS. The kits all had original barrels and I was impressed by the fit and finish of the parts plus the rifles just ran and ran with no problems. They are definitely unique AK variants and I was actually really interested to watch this video and learned quite a bit.
Vladimir actually showed photos of a modified AK-63D that he encountered in Somalia. He mentioned how very impressed he was that it was still running with very little maintenance for close to 20 years.
This is one of Vladimir’s photos of the Somalian AK. Pavel noted it was likely an AK-63D with a cut down barrel, modified gas block and an AMD-65 muzzle break. One can’t help but wonder who did the work and why.
The video is just over 12 minutes and they discuss the early AK-55 rifle that is very similar to the Type 2 AK-47 with a milled receiver. They then move to a discussion of the AKM-63 (I’ve always heard it referred to as the AMD-63 in the US) with its distinctive handguard and grips plus other design differences.
As you may know, I own Ronin’s Grips and we make replica AMD grips. In one of the funniest gun video lines ever, Vladimir noted that the designer who decided to put an identical pistol grip at the front but simply reverse it deserved a medal! The Hungarians wanted to add it to improve accuracy and control under full auto fire.
Both Vladimir and Pavel noted that the front grip made reloading problematic and Vladimir pointed out that he had encountered rifles with the front grip cut down to reduce interference with loading magazines.
I finally got the best explanation ever as to why they used that bluish colored plastic. When the Hungarians decided to experiment with and move to polymer stocks, they lacked the ability to manufacture the base plastic. Because they were a Socialist country aligned with the USSR, the only plastic they could find that they could buy and import was a bluish plastic intended for dish making! You know what, that makes sense to me and what I will explain going forward.
The blue color is because the only plastic they could buy abroad was intended for dish making!
Lastly, they brought up some great examples of unique features you will see in the AKM/AMD rifles:
Distinctive pistol grip design
Metal lower handguard with no gas tube cover
The selector notches are labeled with an infinity diagram for full auto and a “1” for semi-auto.
The rear sight leaf has an “A” on it
The Hungarians used unique selector markings – the infinity loop is for full auto and the “1” is for semi-auto.The rear sight leaf has an “A” on it.
Here’s the video
If you find this post useful, please either buy something using one of the links to eBay and Amazon. With Amazon, if you click on one of our links and then buy something else – even unrelated stuff like clothes, electronics and groceries – we get credit and it would be hugely appreciated. Doing something like the above will help us fund continued development of the blog.
