In my last review, I provided detailed photos of a M70 with maple furniture [click here for that review]. I bought this M70 at the same time and it came with a Polymer furniture set. In taking the rifle apart, I saw the same extensive tooling marks.
In this post, I’ll provide photos and observations for this rifle. In case you are wondering about the setting, it was 15 degrees outside so I did the review in our kitchen – my shop didn’t suddenly grow appliances 🙂
The stock is a Promag Archangel OPFOR four position stock with an adjustable cheekpiece. It’s solid, well thought out and didn’t rattle when I shook it. The pistol grip is a comfortable Tango Down model. Note the recoil pad on the stock.
The stock is adjustable four positions – here it is fully extended. The stock does not fold by the way.
The cheek piece angles upwards in the front by pushiing the grey button. Note the sling swivel quick connect hole.
Top left, the dust cover doesn’t fit flush with the trunnion. The unique recoil spring assembly locking buttonm is just above the top right edge of the side mount rail. Speaking of which, I really wish someone would make and sell this side rail. Zastava USA doesn’t import it. You can see tooling marks on the back of the mag catch housing. The ZPAPs have tons of tooling marks but function well despite them.
In general, I like Hogue’s products. This handguard with the overmolded rubber feels really good in the hand.
Conclusion
I thought about doing a big blog post with a ton of photos showing all the machining marks but decided against it. The rifle and furniture are solid but the metal working lacks refinement. If you’d like to see the detailed photos from a M70 ZPAP with a maple stock bought at the same time as this one, click here.
Zastava turned out a rifle probably to hit a price point and could have done better but at a higher cost. I didn’t expect to like the polymer stock set but I do – the buttstock, grip and handguard all feel solid and feel good when you shoulder the rifle.
Note, I have to buy all of my parts – nothing here was paid for by sponsors, etc. I do make a small amount if you click on an ad and buy something but that is it. You’re getting my real opinion on stuff.
If you find this post useful, please share the link on Facebook, with your friends, etc. Your support is much appreciated and if you have any feedback, please email me at in**@*********ps.com. Please note that for links to other websites, we are only paid if there is an affiliate program such as Avantlink, Impact, Amazon and eBay and only if you purchase something.
I had a chance to get an up close look at a couple of the new Zastava ZPAP M70 rifles recently. The subject of this post arrived wearing a maple furniture set and quite a bit of heft that one would expect from a larger M70 AK vs. an AKM.
To give a bit of background, the ZPAP rifles are based on the military M70B1 rifle with some changes.
A smaller commercial buttstock is used
No grenade launcher gas block
No night sights
A commercial wood grip was used instead of the very ergonomic traditional black polymer model
No bayonet mount
Semi-auto fire control group
A fire control group retaining plate vs. a retaining wire
For whatever reason, when I got “bit” by the AK bug, I really dove into Hungarian, Romanian and Yugo AKs initially. I always liked how the Yugoslavs took the Russian design, made it their own, and turned out some exceptional AK variant rifles. The fit and finish of the Yugo rifles always impressed me.
Well, let’s fast forward to today. I field stripped the rifles, wrote down some notes and took a ton of photos. If there was one general disappointment I found across the rifles it was the abundance of tooling marks. Rather than coming across as a refined AK, the ZPAPs come across as capable bruisers that are rough around the edges.
In terms of cycling, the finish is very smooth and the trigger feels like a typical AK. However, the lack of refinement was disappointing to me. I actually thought about taking it apart and redoing it but don’t have the time.
Now don’t get me entirely wrong – from everything I have read the ZPAP M70s are capable and nothing I saw or felt made me doubt that.
So, let’s get started at the rear and work our way forward on this photo heavy post:
First up is a steel buttpad on the male stock. You can see they are using Torx head screws vs. old school blade or Philips screws. This recoil pad is smaller than the military rubber model found on earlier model rifles – the stock is smaller as well.
Here’s a better view of the Torx screw. You may find it funny that I am making a big deal about their using a Torx screw but it is because I am so fed up with traditional blade and Philips screws on rifle stocks. If the wrong sized screw driver is used then the metal deforms and looks horrible. With a Torx bit, granted it needs to be the right size, but you can really torque on them without deformation.
This model has a maple stock set. Zastava USA offers a number of stock options including sets you buy and swap later. They retained the traditional M70B1 stock attachment method so this opens up a world of surplus and aftermarket stocks including M4 designs.
Here you can see the receiver, the selector lever with a notch cut in it to hold the bolt open, the wood pistol grip and a relatively traditional handguard other than it being made from a ferrule.
The rivets are all over the place in terms of shape and compression. It looks to me like the parts were finished and then assembled. I might be wrong on this but I am trying to figure out why the finish on the rivets looks worn – maybe it was just from rubbing in the box. I’m not sure.
The handguard has a nice pattern from the maple wood in it, They continued the use of a steel ferrule at the rear of the lower handguard to protect the end grain of the wood from the relatively hard and sharp sheet metal receiver.
You can see two very different rivets here. I mentioned earlier that the rivet heads are all over the place in terms of shape and you can see tooling marks even on them.
The dust cover has gaps between it and the trunnion. Ideally, those would not be there.
Peeking inside you can see they have a plate fire control group retaining plate. That’s cool. Note how they use the height of the plate to stop just short of the selector lever hole to keep things in place. That’s a simple and effective idea right there.
They are using a double hook trigger. The disconnector retains the tail from the full auto design. The double wound hammer spring is also very robust..
Interestingly, the selector lever stop is relatively tall on the ZPAP M70s and, unfortunately, you can see tooling marks on it. The selector notches in the receiver are nicely formed.
That’s the side rail for mounting optics and it is unique to Zastava. Nobody else makes this rail so it can be next to impossible to find them unless you buy a ZPAP M70 and use it as a base to build from. The problem with that is you can see all of the clean up required to get rid of the tool marks.
The bolt carrier is flattened with the serial number but there is also an electro-pencil (vibrating etcher) number on the trunnion and other parts – you’ll see them in other photos.
Here’s the electro pencilled serial number on the trunnion. To clarify, I have to assume it was a serial number at least used during assembly.
Here’s another example of the electro pencilled serial number – this time on the rear of the recoil rod assembly. By the way, you can see the operating side of the unique recoil spring assembly lock. Being able to lock the recoil spring part way forward makes installing the dust cover so simple compared to fighting the dust cover into position with the recoil spring assembly having a mind of its own. The lock was originally built in for handling the recoil of rifle grenades but sure makes re-assembly easy as well.
Not too bad. You can see a lot of tooling marks but the notch for the bolt is pretty well done.
Here’s a close up of the groove the bolt’s timing key rides in.
Here’s the bolt in the bolt carrier. The serial numbers are readily apparent on both parts showing they are matching.
Here’s the bolt. They tried to electro pencil the serial number on the hardened steel shaft in the filet shown above but boy, I sure can’t read it.
Machining/tooling marks are everywhere but at the heart is a very robust AK bolt face. You can see a bit of lacquer from the test rounds by the firing pin hole.
Here’s a good view of the chamber end of the barrel and the extractor cut out. Note the slight bevels from about 3pm to 11pm on the barrel face. They would add in reliable feeding no doubt – a cartridge off a but would follow the bevel and go into chamber all things being equal. There is still a riveted bullet guide between the magazine and the barrel.
The fit and finish of the wood overall is very good. The gas tube cover is nicely done.
I wish the metal work was as refined as the woodwork to be honest. The buttstock, grip and handguards are all very well done.
The lower looks good.
A close up of the lower handguard rear ferrule.
This is the lower handguard secured by its retainer. Note the lathe marks on the barrel. I would prefer smooth steel.
Rear sight block
Interestingly, the rear sight leaf is steel colored and the numbers are blackened.
They inscribed the serial number on the elevation adjustment slider.
Handguard retainer and gas block. Note the gas block still has the separate sling ring and no provision for a gas valve that one would see on a military M70 series.
Sling loop and gas block.
In Conclusion
This review dove into details that most AK buyers will not notice. There are tons of reviews and videos of these rifles that show how reliable they operate plus how durable they are by shooting tons of rounds [Click here for Rob’s review at AK Operators Union – he does solid reviews]. I did not have a chance to take this rifle to the range but it felt solid when I function tested it. Honestly, it cycles very smoothly – the tooling marks did not affect function.
The rifle appears solid and has the heft to go with it. While the woodwork was very well done, I honestly found the fit and finish of the metal parts pretty rough. Zastava could turn out a far higher quality weapon if they chose to – I’ve seen it in my military surplus kits. I have to assume they built these rifles with a lower price-point in mind and let the cosmetics issues happen. I hope they choose to turn out a higher end product in the future but in the mean time one of these rifles will give you a big bruiser at a reasonable price.
I hope all the photos give you some food for thought.
Note, I have to buy all of my parts – nothing here was paid for by sponsors, etc. I do make a small amount if you click on an ad and buy something but that is it. You’re getting my real opinion on stuff.
If you find this post useful, please share the link on Facebook, with your friends, etc. Your support is much appreciated and if you have any feedback, please email me at in**@*********ps.com. Please note that for links to other websites, we are only paid if there is an affiliate program such as Avantlink, Impact, Amazon and eBay and only if you purchase something.
My mother-in-law is getting older and so are my wife and I. Let me tell you, It was a lot easier pushing around a wheelchair 10+ years ago compared to today. With this in mind, my wife and been watching for a good deal on one of those little electric mobility scooters. Finally, one day she saw one posted on Facebook at a local thrift store so we want and took a look.
The owner of the store buys abandoned storage units and a Pride Mobility Elite Traveller scooter was in one of them. It looked to be in great shape but it wouldn’t run. He could turn the on/off switch and a light would come on the little dashboard but that was it. He said he tried charging it for an hour but nothing happened and thought it was the batteries — this is a great example of someone giving you their diagnoses and then that affects what you do.
At any rate, it came with the original Pride Mobility charger so I figured it was probably the batteries and did a quick search on them and replacements ranged in price from $51-89/pair. With this in mind, we settled on a price of $250 and brought the scooter home.
Here’s the GoGo Elite Traveller scooter. It’s remarkably well made. I was impressed the minute I started critically looking at the fit, finish and serviceability.
Note: Pride Mobility puts all of their manuals online. I really appreciate it when firms do this. You can get the brochure, owner’s manual, specification sheet and more on their website – click here. Just FYI: They do not provide a repair manual or technical guide.
A few days went buy before I could work on it. The first thing I did was plug the charger into the wall, then the cord direct to the power pack, turned on the switch and the little red power light came on. The charger’s second indicator LED was supposed to turn yellow that it was charging. It did not – it stayed off. Also, the cooling fan never started. Hmmm…. interesting but I had run into problems before with smart chargers not starting if batteries were dead.
Now, this mistaken assumption cost me some time but I learned a lot in the process that I’ll share.
Removing And Opening The Battery Compartment
Based on what I saw, the engineering and build quality of the scooter was excellent. I’ve seen people driving them around but never had the need to look at one up close or take one apart. Everything is built heavy duty with reliability and resiliency in mind not to mention they put fuses all over the place to protect the electronics. With that overview comment done, my focus was on getting to the batteries because I thought that was the problem.
The battery pack is the black plastic “box” with a molded handle directly underneath the seat on the floorboard of the scooter and is held in place by a tab of 3M Dual-Lock fasteners on each side. Dual-Lock is a stronger than traditional velcro and it does a great job of holding the battery compartment in place both for the sake of safety as well as to prevent rattling.
To remove the battery box, lift straight up – there aren’t any bolts or clasps – just a combination of weight, the way the pieces fit together and the Dual-Loc. If you try to lift at an angle, you’ll be surprised how it will not want to budge – straight up is what you need to do.
That black molded plastic object with the handle in front of the silver set mast is the battery compartment. It comes off the scooter by lifting straight up. FYI – the white label on the seat mast has the date of manufacture.
Between the way the compartment sits into the molded floorboard and the 3M Dual-Loc tabs, the unit is very secure.
The battery compartment is very well made and to disassemble it, you need to remove six philips head machine screws. This is just an example of where I thought the design and execution was excellent – these are threaded machine screws that go into brass female inserts on the other side – they didn’t just go cheap using some self tapping screw. You flip the compartment upside down and remove the screws. The batteries are held securely in place by Dual-Lock also.
The 12 Volt Batteries Themselves
I’m going to step you through some details on the batteries but I did not change them yet. I’d recommend you read this whole post because your “problem” may or may not be the batteries.
Our scooter is powered by two 12 volt 14 amp hour batteries wired in series to provide 24 volts. In the compartment is a wiring diagram and everything is done very nicely to avoid confusion – red wires to positive tabs on the battery and black wires to the negative tabs on the battery.
These are the 12 volt 12 amp hour batteries that are hooked up in series to provide 24 volts. If you look to the right of the silver plug, the two red wires white plastic connector is on a fuse assembly that protects the charger circuit that you will want to check and the far right side has a circuit breaker that is also worth checking. Pride says they can go up to 6.7 miles depending on factors such as the weight of the passenger and cargo. Note how everything is so well labeled, the wiring is very neatly done and they even provide a handy wiring diagram above the left battery. Whomever designed and then built this cared about what they were doing.
For those of you unfamiliar with direct current (DC) batteries, these two batteries are hooked up in series to produce 24 volts. This is done by connecting the negative terminal of one battery to the positive of the other and then the opposite as well. In the scooter, this is done at the wiring block in the middle. You don’t need to worry – just note the wires when you take it out (a photo helps) and do a battery at a time – black wire to negative and red wire to positive,
Note, there are at least two sizes of batteries used – their standard battery pack is rated for 6 miles and uses two 12 amp hour (Ah) batteries. There is a 9.7 mile bigger 18 amp hour (Ah) battery and it correspondingly uses a bigger cabinet so if you decide you are going to replace your batteries, confirm what is in your battery compartment first. You can change cabinets – or even buy entire battery packs ready to go. From what I have seen, the cheapest bet is to just buy the batteries and swap them out in your existing compartment. I also see batteries with other capacities like 15Ah and over 20Ah, I’d recommend you confirm that their physical sizes will fit whatever battery compartment you have.
The batteries hold the charge that runs the scooter but they must be recharged by using a battery charger. I should have checked this first but didn’t because I assumed it was the batteries but let me step you through what I did.
I put a voltmeter on each of the 12 volt batteries and they both read just a tad over 4 volts. So, not absolutely dead but boy were they spent. In doing automotive work, I would have expected the smart charger to sense the voltage and begin. Okay, something was fishy and it wasn’t adding up. It was time to look at the charger again.
The scooter came with a Pride Mobility HP8204B charger rated for 24 volts DC at 5 amps. That would mean that if I took my meter and put it on the pins, I should read somewhere around 28+ volts (the exact volts is an “it depends” – I would have been cautiously happy with anything over 24 and stopping somewhere around 30).
This is the original charger. Only a solid red light would come on. That indicated it had power. The cooling fan never turned on and the second LED that should turn yellow for charging or green for fully charged never turned on.
I used my multimeter on the batteries with the Pride charger connected. Only the red bulb on the charger was lit. No fan, no yellow light and no additional voltage detected on the battery terminals. I should have read 13-14 volts when doing the positive and negative tabs on each individual battery with the wires connected but I read just the 4 volts (by the way I word it like this because it was 4 and some decimal but I didn’t write down.)
The fuse you can see outside of the battery pack between the plug and a circuit breaker on the front of the battery pack looked fine and tested okay for continuity.
In looking at the battery pack, I unplugged the pin 1 should have been positive and pin 2 should have been negative. I cautiously touched my probes on the two tips because I didn’t want to unnecessarily short the system out by accidentally touching positive and negative together. Guess what? Nothing – not a thing. My auto-ranging digital meter was doing it’s usual millivolt reading garbage but there was no real voltage coming through.
The next thing I did was to turn off the original charger and remove the fuse from the end of the charger with the lights – undoing the round cap will produce a glass tube fuse. You can usually see if the wire running from one end to the other in the middle of the clear glass is intact or burned out. It looked okay and just to be sure I ran a continuity test with my meter and it was okay.
I also pulled apart the plug that goes into the battery pack just in case something was lose and it read zero volts too. In case you are wondering why there are three pins (I wondered why) – pin three provides voltage to the scooter so the little computer knows the charger is still attached and will not let the driver move the scooter – pretty good idea.
Okay, it was time to Google the scooter and the charger to learn more. The fact that only the red light was coming on but not the fan and/or the yellow charging light was making it look the the charger had failed. I did the “sniff” test to see if I could smell if anything had burned out but if it had, it must have been some time ago as I didn’t detect anything. In short, the charger was history.
There are tons of charger options on Amazon but I want to caution you against the little sealed chargers. They do work but they are going to get hot and they will probably fail at some point due to all of that heat. There’s a reason Pride went with the a fan cooled charger – they get hot converting AC (wall outlet) current to 24 volts DC (direct current).
Companies like Pride rarely make their own chargers. They will either use an existing charger on the market and not bother covering up the name of the maker or they will pay for it have their brand name on the decal. Pride opted for the latter or at least that’s what I think they did. The trick to realize here is that by searching on HP8204B, you can find either the original maker or another firm who did the same thing – had their name put on the charger. Regardless, you can save a bundle off a new Pride charger.
In my case, I found a seller named “ENCAREFOR” on Amazon selling what seemed to be the exact same charger but with the label “High Power” on it. Besides the label, the rated output is at 4 amps vs. 5 which means it will just charge a tad slower. It was going for $89.99 with Prime One Day shipping but I held off as I realized I needed to test the batteries and the scooter before I spent more money. In other words, I knew the charger was bad but didn’t want to spend more money if the scooter itself was burned out – if it was just the batteries, I could still order them.
By the way, you can buy used OEM Pride chargers off of eBay. I’ve had mixed experience with used chargers in general so I tend to just buy new. If you don’t mind gambling on a used one, they are on eBay.
Used a Noco Genius Car Battery Charger For Testing
At this point I was pretty sure it was charger and also thought that the batteries might be okay. Why? First off, there is a sticker on the mast pole of the seat that said the scooter was made in 2019 – that meant it was three or just under three years old (especially given I was doing my troubleshooting in mid-February 2022). Batteries can last maybe five years give or take. If the voltage was zero, I’d bet they were junk but since I was getting just over 4 volts from each battery independently, they weren’t completely dead. I started to wonder if a good reconditioning and charge might work to bring them back to life. I had just the charger to try.
Any 12 bolt charger can do the job provided you charge the batteries one at a time.
I undid the battery cables from the first battery only and directly connected the Noco to it. I charged for one cycle and then ran a repair cycle. During repair, the charger pulses the battery to desulfinate it.
Don’t let all the wires intimidate you. I hooked the plus (red) clamp of the Noco to the plus (red) terminal of the battery on the left, I then hooked the negative (black) clamp from the Noco to the black terminal of the same battery. I have a small voltmeter that clamps ,on attached also so I could monitor progress — that’s strictly optional.
Results
When the charging was done with both batteries, I connected the scooter’s cables back and seated the battery back into its cradle. I then turned the key on for the scooter and moved it forward and backward. It worked just fine. I checked the batteries and the voltage was holding – it wasn’t dropping down.
This is what I wanted to see — the batteries were fully charged. I drove the scooter around the house and the charge never went down. I also learned that scooters are bizarre little things to drive – their turning is like sitting upright on sensitive go cart.
Other than the decals and the lower 4 amp output, the new “High Power” charger looks identical to the Pride unit. Note, I’d opened the front of the unit up to inspect the inside — the front panel is what is dangling in the bottom left of the photo.
As soon as I plugged in the new charger and turned it on, the red power light and yellow charging lights came on.
By the way, the charger’s fan will make a pulsing or surging sound as the speed changes as it nears the end of charging. This is normal and will give you an indicator that charging is almost complete.
When the scooter’s batteries are fully charged, the yellow light will turn green. The fan will make a pulsing sound as the charging nears completion.
Bottom line, the batteries and scooter were fine – it was just the charger that had failed so I ordered the replacement above from Amazon and it topped off the batteries. I drove it around the house some and everything was working just fine.
In Conclusion
So I learned a few things. The scooter was exceptionally well made is my first comment. Second, I should have started from the wall and worked towards the scooter vs. focusing on the batteries to start based on what the fellow told me.
I should have confirmed power to the charger, then that there was no power from the charger to the scooter and ordered a new charger. I’d bet a new charger could have recovered the batteries – the documentation says they can recondition a battery but who knows. Even though I started with the battery, at least I could run the Noco charger through charging and repair cycles – I’ve used it to recover a number of really compromised batteries over the years.
The scooter is ready and now we need to wait for warmer weather to let my mother-in-law practice in the driveway. I hope this story helps you out.
Note, I have to buy all of my parts – nothing here was paid for by sponsors, etc. I do make a small amount if you click on an ad and buy something but that is it. You’re getting my real opinion on stuff.
If you find this post useful, please share the link on Facebook, with your friends, etc. Your support is much appreciated and if you have any feedback, please email me at in**@*********ps.com. Please note that for links to other websites, we are only paid if there is an affiliate program such as Avantlink, Impact, Amazon and eBay and only if you purchase something.
I’ve had a few guys ask me about my experience with the Palmetto State Armory AK-V and if I thought it was worth it. Well, I bought mine on July 20, 2019 and it was solid right out of the box. Although I did do a bunch of customizations, none of those changes were to improve reliability – they were all cosmetic.
An AK-V is basically an AK that has a blow back operating system to handle the little 9×19 (or 9mm Luger) cartridge. They did have some initial problems with the design such as cartridges getting stuck under the dust cover, they had fixed them by the time I bought mine.
This is my AK-V right out of the box still sporting the Magpul MOE grip, handguard and SBA-3 brace.
Palmetto State Armory (PSA) has a stunning array of Kalashnikov firearms now. AK-47s, AK74s, 100 series, rifles, pistols … it’s impressive. Click here to go to their main AK menu.
The biggest problem I had was finding one. There were a bunch of us watching the PSA website trying to snag any model we could. Finally, on July 1, 2019, I snagged one of their MOE SBA3 models and proceeded to change it to my liking – first with an SBA4 brace and then to look more like a Vintorez. [Click here for a listing of all of my posts on the AK-V].
This was my AK-V after my first round of modifications – I move to the stiffer SBA-4 brace, added one of our quick takedown rings so I could get the dust cover out of the way when cleaning the pistol and one of the Vortex Crossfire red dots.
This is my current confiruation – a CNC Warrior/Bonesteel Arms side folding brace (they are way beefier than the side folding triangles PSA sells), K-Var handguards and one of our Molot Gen 2 grips.
To be very clear, I bought it so I can saw whatever I want about my experience.
I really had fun with the little braced pistol and found it reliable, accurate and just an all around fun little gun to shoot. The good news is that for people looking for AK-Vs now, PSA production has finally caught up and you can hop right over to their website and buy one.
I do want to give you a tip for breaking in the AK-V before your first range trip:
Field strip the rifle
Clean the bore and make sure the action doesn’t have any junk in it.
Oil the fire control group
Use a light grease on the frame rails, where the bolt goes into the bolt carrier and on the bottom. You can switch to oil but the grease really helps lubricate things druing the wear in period — If you are in cold weather, say below 30F, then use oil as the grease will be too thick.
Reassemble the AK-V
Without a magazine in the AK-V, rack the slide (meaning move it back and forth) a couple hundred times to help the wear in process get started. You do not need to use anything abrasive to wear things in – I’ve heard of folks using valve compound to accelerate wear in but it’s just not needed 99.9% of the time.
I would also recommend using a stout/strong/stiff load initially. Rather than 115gr FMJ ball ammo, I will use 124gr FMJ as it generates more of a recoil impulse. I use 124gr Sellier & Bellot (S&B) FMJ 9mm a lot for this.
After a few hundred rounds you can shoot anything you want and it will cycle.
I kid, you not, this can make a world of difference when you go to the range the first time. What I find frequently happens is that a new gun owner gets excited and takes his/her brand new purchase right out of the box at the range, loads it and then gets upset at the weapon and labels it as an unreliable POS, which isn’t fair. I always tell new owners to do the above for any semi-automatic firearm.
Another view
Here it is with the brace folded. I would have preferred a left-folding brace but CNC Warrior was sold ouut so I opted for the rifle-folding model. Regardless of the model, this is the best in class folding triangle brace and I highly recommend it.
So, with that said, get an AK-V, do the above to break it in and have fun. There is a huge parts aftermarket for the AK rifles and pistol and I am sure you’ll enjoy it.
Note, I have to buy all of my parts – nothing here was paid for by sponsors, etc. I do make a small amount if you click on an ad and buy something but that is it. You’re getting my real opinion on stuff.
If you find this post useful, please share the link on Facebook, with your friends, etc. Your support is much appreciated and if you have any feedback, please email me at in**@*********ps.com. Please note that for links to other websites, we are only paid if there is an affiliate program such as Avantlink, Impact, Amazon and eBay and only if you purchase something.
Second on the list of things I needed to fix right after the buttstock was the loose handguard. It’s a personal preference thing but I don’t like handguards that wiggle and this thing could move front to back as well as side to side. The reason this happens is usually because the handguard retaining slot on the barrel was cut too far forward such that the cam lever on the retainer couldn’t push the handguard far enough backward.
I expected this. Classic Firearms, and presumably James River Arms (JRA) were up front in the product listing that the handguard would probably be loose and it was. Thankfully, from years of working on AK rifles, I knew I had a number of options:
I could weld the handguard retainer channel closed on the barrel and cut a new one. Pro – the right way to do it. Con – would take more time than I wanted to invest.
Some guys will add layers of epoxy liquid or putty inside the retainer but I am not a huge fan of that one due to the epoxy getting warm and likely breaking down under the relatively sharp edge of the sheet metal nose of the Galil handguard.
I could extend the front edge of the handguard retainer by building it up with small welds. Pro – easier than redoing the barrel channel. Con – would take more time than I wanted plus it’s really hot out and welding did not sound pleasant.
I could fabricate some shims and insert them into the handguard retainer. Pro – an age old method with soliders putting everything from wood and gum wrappers to folded steel and aluminum cans in there Cons – can fall out when you remove the handguard.
I opted for the fourth one and decided to make shims. You’ll notice a common theme – I do not have a ton of time and am dancing around the battle worn theme with the rifle leaning more towards the newer end of the spectrum vs. extremely worn.
To shim a handguard, I prefer a metal vs. wood, paper or plastic as they tend to all break down with time. An age old trick on the AK community is to take an aluminum soda or beer can and then cut either into strips or in an approximate shape that fits inside the retainer.
The shape of the Galil handguard added a bit of a challenge in that it is a “U” shaped piece of sheet metal that slides into the retainer. The front edge is relatively thin vs. the old days of a big thick piece of wood or plastic going into the retainer. This approach can be seen elsewhere also such as in modern Bulgarian and Russian handguards.
So, given the shapes of the handguard and the retainer,I decided to cut two strips that would closely fit between the barrel and the inside lip of the retainer and also be sufficiently think to secure the handguard. Given the “U” shape I was betting that I would get enough support from the left and right sides and that I would not need to worry about supporting the bottom.
I measured the gap from the barrel to the inside wall/edge of the retainer on the left and right sides and it was about 6mm (0.236″). That meant I needed something that either started at a 1/4″ and grind it down or find something closer to 6mm.
My first try was to look for 6mm wide shim sets and none was to be had. A shim set or shim assortment is a collection of steel of varying thicknesses so you can combine whatever thicknesses you neeed to get your final thickness plus you cut them to what is needed.
I ordered in a steel shim assortment set as I haven’t needed any for quite a long time. I also scrounged around for what sheet metal I had in stock. I had some rediculously thick 16 (0.0598″) and 18 (0.0478″) gauge pieces plus a good sized piece of 22 gauge (0.0299″) sheet metal. I decided to start with the 22 gauge set and fine tune with the shim assortment but a bigger question was forming – what did I have to cut this stuff cleanly that wouldn’t make a big mess.
Good old fashioned sheet metal shears / tin snips were an option but I’ve never been that consitent with the things. I had an air nibbler that I could set up with a straight edge to cut strips … and then it dawned on that I had a Harbor Freight 14 gauge swivel head double cut sheer (item #92115) that might do the trick and – here’s the plus – it cuts a metal strip out of the source stock to avoid deformation.
I dug the thing out and lubed the cutter. It had probably been at least a year since I had used it. Guess what? That “waste” strip turned out to be about 6mm and gave me what I needed.
Here’s the business end of the double cut shear. Note the strip it cuts out. I just ran it into the stock with a straight edge just to keep the donor sheet clean and had all I needed and then some in a few seconds of actual cutting.
Plain 22 gauge sheet metal is 0.029″ thick and I knew I had a fair sized gap to address so I tried folding it in half and then trimmed to to fit in each side of the handguard. The best way I found for test fitting was to clamp the whole rifle with the muzzle down in my big woodworking vise. From there I could rest the shims in the handguard retainer, insert the handguard and pull up on everything trying to get the locking lever to flip.
Much to my surprise, that double thickness of the sheet metal worked perfectly. I had expected to get close and then keep adding pieces of shim stock until I had a solid lock up.
The next thing I had to consider was how to hold the shims in place when I normally assembled the rifle. I decided to keep things simple – I super glued them in. My reasoning was that I rarely take off handguards and if the two shims fell out in the future I could glue them back.
These are the two shims. Notice I made them as long as I could for each siide but I did not make one for the bottom and that has not proven to be a problem thus far.
Now one thing was still bugging me – there was too much movement left to right in the retainer as well. What I did to fix that was to glue a shim on on the outside edge of one part of the metal handguard’s front steel U-shaped nose.
Here is the single 22 ga shim I needed to stop lateral movement. It turned out that the shim was visible in the gap between the retainer and the handguard, I wound up painting it with some of the Rustoleum Satin Black pain also.With the shim painted black, you don’t even know it is there.
The Results
The handguard is now rock solid. I decided not to change the wood at all. I really like the coloring and for me it’s really part of the iconic look of this rifle.
With the handguard done, next up was to switch the fire control group to an ALG enhanced set so I can have the appropriate 922r parts count and be able to use some of the cool IMI surplus mags that are out there.
Note, I have to buy all of my parts – nothing here was paid for by sponsors, etc. I do make a small amount if you click on an ad and buy something but that is it. You’re getting my real opinion on stuff.
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The first thing I decided to do was to replace the buttstock and it was purely for cosmetics – the original locked up solid and did the job. I happen to have two SAR kits that I hope to build some day so I could look at them and pick parts. It just so happened that one of the SAR kits had a stock that was in much, much better shape.
The buttstock assembly I planned to use came from a SAR kit I had. The barrel stub has the night sight and I was thinking of moving the flip sight to the Gallant but changed my mind. I figured I could at a later date should I want to but I also realistically knew I would never need them. My goal was to get the Gallant into the shape I wanted it – not to build a perfect replica.
A Galil buttstock is press fit into the rear of the rear of the receiver and held in place by a roll pin that goes through each side of the receiver.
To remove the stock, first punch out the pin using a roll pin punch. These punches have a small round hemisphere in the middle that sits inside the roll pin and the shoulder of the punch rests on the walls on the pin that enables for the punch to properly drive out the pin with even support all the way aroud.
The SAR receiver stub is supported by a bench block and I am using a roll pin punch with a hammer to drive the roll pin straight out. I used a 3/8″ brass rod and hammer to drive the stock out of the stub and also out of the Gallant’s receiver.
To drive the stock back out of the receiver, I would recommend a 3/8″ brass rod cut to whatever length you want/need. Before the brass rid, I tried a hardwood dowel but the end simply broke apart against the metal insert. The stronger brass rod and a hammer made quick work of pushing the stock back out without harming the surrounding steel.
Here is the stock that came with the Gallant. I used the 3/8″ brass rod and ball pein hammer to drive/knock the butt stock out of the receiver .
I used a rubber dead blow hammer and whacked the new stock back into position. I had locked the stock in the open position and was striking the buttplate that I planned on refinishing anways.
One challenge was that tnew stock’s holes did not line up with the receiver’s holes so. I egged the hole slightly and filled the gap with epoxy, If I ever want to improve the looks, I’ll either weld the holes shut and re-drill them or go to the next size larger roll pin. I guess I just figured they would line up given it was Israeli but it’s not a big deal.
In terms of preparing the replacement stock, I used 0000 steel wool to smooth the horizontal polymer rod. and then applied Rustoleum Satin Black on the metal. What was on both stocks seemed to be something enamalish so I opted to brush on a finish using a foam brush. I did two coats at let it dry for a day before I handled it. Note, bore solvents and what not will probably attack the Rustoleoum so I’ll just try to minimize contact for now.
It came out better than I expected but it was shinier than I wanted. I let the paint harden for a couple more days and then I used 0000 steel wool to knock down the shine. What happens is that the very fine steel wool immparts very small scratches to the surface thus removing the shine. If I had it do do over, I would still use Rusoleum but I would have used flat black. If I really wanted to go nuts, I could have taken everything apart, blasted and parked the steel surface, apply Molyresin or Cerakote, bake it and then reassemble.
The first coat of Rustoleum Satin Black is on the two aluminum portions of the buttstock – the lower angled tube and the rear. The top is some form of black polymer that I ran over with 0000 steel wool. Note how shiny the paint is. After it had a few days to harden I then knocked down the shine by lightly going over it also with 0000 steel wool.
Again, my goal was to roughly stick with a batte worn look vs brand new from the factory. If I ever change my mind, I can always go that route also. A friend once told me that once you get into building guns, it’s kind of like Barbie Dress Up for men. You can change all kinds of stuff whenever you want and your two big constraints will always be time and money.
It came out pretty good. I left the steel folder surfaces alone.
So, the final product look came out pretty good – I wanted “worn and mismatched” and that’s what I stil had. Just a tad bit more to my taste. Next up was to fix the handguards so they weren’t so loose.
Note, I have to buy all of my parts – nothing here was paid for by sponsors, etc. I do make a small amount if you click on an ad and buy something but that is it. You’re getting my real opinion on stuff.
If you find this post useful, please share the link on Facebook, with your friends, etc. Your support is much appreciated and if you have any feedback, please email me at in**@*********ps.com. Please note that for links to other websites, we are only paid if there is an affiliate program such as Avantlink, Impact, Amazon and eBay and only if you purchase something.
A reader dropped me an email and asked if I am doing anything new this year for mosquitoes as he read my past posts. I’m still very happy with the effectiveness of the Talstar insecticide plus the combination of the Ryobi 120350 Power Washer and 10-gallon tank strapped to a dolly continues to work fantastic.
I hope everyone has a great summer and be sure to nuke the bugs before they get to you 🙂
5/21/23 Update – still using the same set up. Everything is working great, Power washer is holding up just fine by the looks of it. I just did my first spray of the season last Monday.
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Lest We Forget is an organization dedicated to keeping the memories of what our military has done for us. The 2019 event was the last one for WWII, 2020 was cancelled due to COVID and 2021, this year’s event, remembered Korean War veterans. They have static displays, food, vehicles you can ride on and re-enactments.
We arrived a bit late on June 19th due to family commitments but I did have a chance to snap some photos of the various vehicles on display that including a M3 halftrack, a DUKW 6×6 amphibian, an M37 dodge and a M59 APC to name a few.
Here’s the slideshow:
If you ever get a chance to attend a Lest We Forget event, I highly recommend it. The atmosphere is family oriented and everyone there wants to share and have a good time.
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