Making the Gerat 05

In the last post I showed you some of the parts that had been made for the 06, this time we will chat about the o5 and do a little more detail about the making of it.

The life of the 05 starts out like any other pressing as a water jet cut flat. The initial flat were made with my band saw and file until it is some what close to what I need. Then they were stamped and checked.

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Then drawings are made up based upon our findings and 10 flats are water jetted out. They are pressed and cut to determine if the metal is moving properly in the die. The final pressings are checked and measured to see if it correct. Then the drawings are again changed and 10 more flats ordered and re-stamped and the process is started all over again. Some where between the 8th and 12th time we finally have a product that we want. Once we have the flats are correct and we feel that they are ready I determine the number that I am going to make. In the case of the 05 I want to make 50 complete rifles with the possibility of making 100 total if they sell. So I order 120 flats. In theory that should make 60 receivers. However, if truth be know I am hoping to get 50 complete rifles at of that number. With each step that we take, fixtures have to be made, milling has to completed, welding set ups need to be design and tested so by the time I get to the final product a certain number of them will be reduced to scrap.

IMG_1661sIn this picture you can see one of the test sets that we stamped a year ago. This is  3 out of 4 receivers that we made. All of them have problems of one sort or another. On the center one the cut for the mag housing was to far back and the lower on has a similar problem but to close to the mag housing. There was also a tearing problem on them as well. the top of the mad well was not pressing correctly and we changed the design and dimensions of the front angle piece. At the end of this process we though we had a correct design, that was not to be correct.

IMG_1660sThese 5 receiver flat are the latest batch of test pieces that we made. This group came after doing a series of test pieces were we changed the flat design and the stamping dies. There are also major problems with every one of the flats. All but the last one tore and they all had problems with the upper corner of the magazine housing.

IMG_1675scThis picture shows the tearing.

IMG_1707scAnother problem was the design of the flat.

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This one shows that the flat design was not correct and would have to be changed as it left to much metal up close to the barrel extension.

IMG_1709sIn addition to the visible problems we have to cut a few of them to check metal thickness after stamping.

IMG_1667csThe dies were changed again to insure the proper metal thickness.

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A few more pictures of the same stampings before and after modifying the dies.

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IMG_1668sSo now with the stampings checked and re-checked we are ready to stamp out the right side receiver. From start to finish the process has taken about a year and over 100 bad stampings have been made. The good news is with the right side completed we can now used that knowledge to reduce the number of bad stampings on the left side of the receiver. Until next time.

The Gerat 06

Now that I have spilled the beans concerning the Gerat 06 here is the progress so far on the rifle. All the receiver half’s have been pressed.

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Here are a couple of close up pictures of the receiver.

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The sight bases have also been pressed.

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IMG_1018sThe end caps for the butt stocks are completed.

IMG_1016sThe triggers are completed.

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IMG_1025sThe inner mag housings are completed.

IMG_1022sAnd the barrel end caps are completed as well.

IMG_1024sWe are currently keeping the cnc machining centers busy with the VG1-5 parts, however as soon as we have completed those parts the 06 will be next.

The other projects at Gun Lab

I did a little slipping in the machine gun shot video about one of the projects that we are also working on. That is the Gerat 06. There was only 4 of these weapons ever made before the Germans shifted to the STg45 instead. We are planning on doing 14 of them.

pattern room 270csThe other rifle that is also on the production line is the Gerat 05. This was a concept rifle only as no were ever made. This rifle is the only copy of one and I like it so much that I decided to do a run of 60 of them.

8-13-06a 091acsThis is a picture of me shooting it.DSCN0076aaAnd a close up of it.

8-13-06a 093csBoth of these rifles are gas operated roller lock design. the little wood stocked one is pattern after the Gerat 03 that was made in 7.92x57mm. Both of these rifles are in 7.92×33 kurtz. Both rifles take the standard stg magazine as well as the 10 round ones that we make.

So as we are finishing up the VG1-5 I will also start posting about both of these weapons. Until next time.

Video from the machine gun shoot.

I have finally managed to complete a basic video from the machine gun shoot.Now it is back to work for me.

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What I did last weekend

I know, I know. I should have chained myself to the milling machine or the lathe and work through the weekend like I normally do, instead I went out and had some fun.My son, wife and I went to a local machine and cannon shoot and had a great time. I am working on a video to show all the fun we had. As a teaser I shot and played with the following toys.MG-42, MG-34, Gatling gun, 13.7 Japanese machine gun, 50mm Krupp cannon, full auto Fal, Bren, STg-44, 1950 madsen smg, pps 43, and 30 or 40 other weapons that slip my mind. Video to follow.

Up date on the project.

Here at Gun Lab. net we have been working on a number of projects. Quite a few videos have been made and as soon as I can get Ian down to help me correct the problems with Pinnacle studio they will be posted. Some of the projects are new stamping dies for various parts that have to be made and a number of them are the actual parts that are now completed.

I thought I would give you an up date on the  rifle that we are currently working on. IMG_0006csThis next batch of pictures deals with all the parts that have been made and the various stages that they are in.

IMG_0962sAll the rear barrel supports are completed.

IMG_0991sAll the hammers are machined but not heat treated.

IMG_0953sThe cross pin for the rear barrel support is machined and threaded.

IMG_0966sAll the front barrel supports are 90% machined. the retaining notch needs to be cut and that will be done after all the upper receivers have been machined.

IMG_0951sIMG_0952sMisc cross pieces and been cut and stamped.

IMG_0988sThe gas pistons are machined. We just received the tap in this week. We will have it threaded this coning week.

IMG_0943cAll the rear sights are machined.

IMG_0947sAll the extractors are here, we are using H&K extractors as they are the same basic style.

IMG_0957sAll the extra extractor springs are here, again H&K.

IMG_0968sIMG_0970sAll the rear top covers have gone through the first stamping op and 20 or so have been completed.

IMG_0974sAll the end caps for the rear top cover have been cut out,

IMG_0975sAll the barrel blanks are here. We are using MG-13 barrels are our basic blank. No they are not rusted just covered with grease and dirt.

IMG_1012csIMG_1014sThe receivers have been stamped.

IMG_0944sMag catches are complete. The button and post are in the works.IMG_0949sThe triggers are completed and heat treated.

IMG_0945sThe front barrel support take down spring are finished.

IMG_0948The buffer springs are here as well.

IMG_1001sIMG_1000sAll the upper receivers are cut to length and turned to the proper diameter. And the first 10 are turn on the inside. Only one has been completed and fully machined. This our test and fit sample.

IMG_0963sThe mag housings are completed.

IMG_1073sThe upper receiver guides are machined.

IMG_0960sIMG_0958sThe test batch of the newly design primary and secondary sear and the new disconnector.

IMG_0977sThe new fire control group housing is now design and ready for testing.

IMG_0954sAll the strengthening plats are cut out and ready for bending.

IMG_0956sThe newly design receiver support has been cut out, bent and tested for proper fit.

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All the safety’s are cut out and just need to be bent.

 

I have more pictures to take for the rest of the parts that are completed. I will update soon.

 

 

 

Time at the big press

Today is pressing day. We received the flats back from the water jet people and they look great.

IMG_0856cA second picture of the pile.

IMG_0861cSo out to work to get this project back on schedule.

IMG_0878cThe first package is complete and on to the rest.

IMG_0880cThe second package is now complete. It takes 5 hits from my big press to do a single top cover.

IMG_0882cThis is it looks like after this op.

IMG_0883cAlmost done. Just one package left to complete.IMG_0884cWell it is done. I have found the flat that I’ve been looking for all day. And would you not know it but it was hiding on the bottom of the stack. So this is the little sneaky one.

IMG_0889cHere are a few pictures of the operation. The first is the flat in the die and centered.

IMG_0890cThis next picture is as the die starts to close.

IMG_0891cThis next photo is the die fully closed and the pressing complete.IMG_0892cThis one is what it looks like after opening the die.

IMG_0894cNow for the picture you have been waiting for. The final flat stamped. Front and back.

IMG_0895c IMG_0896cThis is a photo of all the flats pressed. I hope you enjoyed the day at Gun Lab I will chat with you soon.IMG_0898c

 

 

6th op on the front barrel support.

By now I am sure you are wondering when will this front barrel support be done. Come on and lets make something else. Well, not quite yet. This is the last operation that will be completed on the cnc lathe.

Now the last step after this is the knurling and then machining the notch for the locking spring.

Update for the week ending 2-1-14

So we will start with the update on the VG1-5 project. I stamped the rear top covers.Out of the 10 that were stamped.third flat style (4)s

We found a few problems. I had to re-stamp the parts due to not getting the ribs deep enough.

IMG_0717swThis is a close up of the stamping.

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Once I re stamped them they looked good for the next step. This showed us that we need to change the basic design again. I hope to have those flats this next week. It should be the last change. Once verified I will stamp all of them. I will be glade to finish these parts. I need to get on to other parts that need stamping. This is a quick picture of the top cover installed on our prototype rifle.

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On to other things completed this week/weekend. We have made a new machining fixture for the hammers. The previous one had tolerance issues. We also have to re-ream the pivot hole on the hammers. They were undersized. Not a big set back, just another day reworking parts. To allow us to re-ream the hole we are using a real basic fixture that has been dialed in on the Webb mill. A pile of hammers to re-work.

IMG_0210sThis is the set up.

IMG_0741sBy using the round part of the hammer in the v portion of the vise and the flat of the hammer against the solid vise jaw I can get repeatably. This vise will set inside my kurt vise  be zeroed in.

More work was completed on the fab shop. I have finished the windows and outside of the wall.

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The inside which will also be covered with osb is about 50% completed.

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I finished the frame for the evap cooler and hope to have it up and running before the summer season.

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The Type 99 female die.

Now that the male die is complete, with only de-burring left to do, it is time to start on the female dies.IMG_0554s

As with the male die it starts out as a large block of steel.

IMG_0545sWith this die we made it in three parts. This allowed us to machine areas that would be very completed.

IMG_0591sAt this point you will notice the alignment pin holes between the upper and lower dies.

IMG_0596swAfter the lower die is completed a backing plate was made and then ground to hold the completed die together.

IMG_0655sThis is the completed die attached to the plate.

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IMG_0668csWith this step completed we will be drilling the holes for attachment to the die plate. That will be this weekend. I will post about that when completed.