Custom Carbon Fiber Handguard

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3 years 11 months ago #162 by michael
michael replied the topic: Custom Carbon Fiber Handguard
Yes, I'm stupid...I frequently have dreams that solve problems I run into during the workday. Sometimes, I solve problems I didn't know about - it's neat.

Last night, I had 2 dreams. One was completely unrelated - and the other pointed out that I didn't take into account the gas tube. Yes, my nifty plan to make a CF handguard was dashed by a dream.

No matter - I still plan on making it, I just have to figure out the new CF diameters and determine what dimension my spacers must be.

Anyone need a 40mm OD CF tube?

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3 years 11 months ago #163 by michael
michael replied the topic: Custom Carbon Fiber Handguard

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So, the tube I should have ordered is this one:



I'm using cad to design my spacers. This is actually working out well, because I think I've designed something very unique.

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3 years 11 months ago #176 by michael
michael replied the topic: Custom Carbon Fiber Handguard

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Looks like the cheaper - but more tool-like Sunex crows foot 1 3/16" is too wide for the Mentium barrel nut

So, I've ordered the Mentium crows foot... Kinda pissed - but what can I do? I heard that Snap-on makes one that's thin enough - but at this point I think I'll stop wasting money on things that might work.

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3 years 11 months ago #177 by michael
michael replied the topic: Custom Carbon Fiber Handguard
So, before I run off and order what I believe to be the correct diameter CF tube - I'm going to be taking more precise measurements on the barrel nut, as well as identifying the thread pattern and making some preliminary mounting hardware.

The 24 barrel nut threaded mounting holes are in 2 rows with each consecutive hole being 30 degrees apart.

I think I'll take some aluminum bar stock and drill it to accommodate 2 screws on the barrel nut (counter sunk) and thread 3 (in between) to screw through the carbon fiber tube. I think 6 of these bars should do nicely - and will leave a gap for the gas tube.

Pictures and measurements coming soon.

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3 years 11 months ago #180 by michael
michael replied the topic: Custom Carbon Fiber Handguard
1ST MEASUREMENT TIME!

OK, the barrel nut arrived today - so I can take my first measurement. it's true diameter is 1.38in/35.05mm (as opposed to the 35.56mm number given by the mfg) - so a half mm off, nothing that's going to hurt the project. My pre-made CF tubing options are limited. For the most part, I can get 1.5mm thickness or 2mm thickness, and once you arrive at 40mm OD, everything above that is in 10mm increments. I measured the OD of the CF handguard I already have and it's just shy of 50mm, so I know that size will accommodate the gas tube. That's what I ordered 50mm OD x 46mm ID.

That leaves me with an 11mm gap to fill. Distributed, I need 5.5mm spacers between the barrel nut and the handguard. That thin, I'm concerned about tapping the aluminum spacer. 5mm isn't really much, so I'm thinking the screws will pass through the spacer into the barrel nut tapped holes. Not sure how I'll get them in place though.

I wish I had a lathe

I'm going to have leftover CF tube. I may cut it into strips and glue them in place - then drill my mounting holes through the triple-thick CF tube....
The following user(s) said Thank You: Buildingdoc

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3 years 11 months ago #181 by michael
michael replied the topic: Custom Carbon Fiber Handguard
Consulting my taps, the 24 threaded holes are 10-32

I can't really do anything else until the CF tube arrives - so until then

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