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M249 SAR Project (Page 1 of 5)
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Posted: 2/6/2012 10:42:05 AM EDT
[Last Edit: rncbinc]
Hello all, I am new to the forum so I don't know if this is the right place to post or not.  I am doing an M249 SAR, a project I have been looking to do for some time but have just now found the $ and time. I will post pictures during the process for those who are interested and since I never just make one of anything in my shop I will most likely have extra parts and may be able to help out others who are doing a similar build. Ya, I know...what's the point of a semi-auto belt fed!  Nothing, it is just for fun and to say I could build one. Plus it looks cool on display and reminds me of my days back in the Corps when I had to lug the SOB around.  If anyone has any tips or tricks from their build that they would like to share, by all means post them up.  My parts kit is inbound as well has my blueprints so I will post when they get here.  I think they will be paper copies so I will put them into Autocad for easy changes.  Budget for the project is $6K

Side note: I thought it might be interesting to keep a running total of the cost to date: $5656.00
FN Blueprints and factory weld specs-
Reciever Channel and Gas Tube Suport shipped- $172.00
Complete parts kit, used condition shipped- $3026.00 (Not as complete as I thought, but odd part will re-sell)
Trunion, 3 rail set and rear bridge- $754.00 (Rear bridge was a flat not bent so that goes into the re-sell pile too)
Bridge, Pintle mount, Trigger mount and a bag of pins, springs and screws $375.00
New Bi-pod (other one was for an M240 which I hope to resell for $200+) $130.00
Trade in FA operating group for upgraded SA operating group $250.00
Another batch of small parts $200.00
Sale of extra parts -$400.00
Heat treatment trunnion-$45.00
Additonal Top Cover for parts, some will re-sell $348.00
Replacement Rail, Trigger Pack and Bushing $502.00
Picatiny Rail stock $25.00
Norrels Moly Resin Finish $29.00
Sale of extra parts $100
2nd Barrel $300
Another new Bi-pod $200
Sale of more extra parts $200
Link Posted: 2/6/2012 2:33:26 PM EDT
[#1]
Looking foroward to your pictures.
Link Posted: 2/6/2012 2:36:59 PM EDT
[#2]
Needs a slidefire type stock.
Link Posted: 2/7/2012 8:05:01 AM EDT
[#3]
Loving the idea!  Keep us posted with pics and developements.
Link Posted: 2/8/2012 1:42:51 AM EDT
[#4]
Tag, this is relevant to my interests.
Link Posted: 2/8/2012 10:46:34 PM EDT
[#5]
Originally Posted By shade_1313:
Tag, this is relevant to my interests.


This.
Link Posted: 2/8/2012 11:06:27 PM EDT
[#6]
Any Pics?
 
Link Posted: 2/13/2012 5:21:56 PM EDT
[#7]
Well the first of many parts have arrived, channel and gas tube support.  No prints yet so I can't check the specs on the receiver channel to see if they are off or not. I look like I will have to do a bit of machining on the channel and I am still undecided if I will do a true M249 or an Mk46.  I think that will depend on if I can find a magazine feed weldment or not. Finally found a supplier for trunnion and rear bridge but waiting on more funds.

Link Posted: 2/21/2012 4:23:02 PM EDT
[#8]


TAG
Link Posted: 2/23/2012 8:13:18 PM EDT
[#9]
More parts have arrived.  Looks ok...some parts need to be refinished and I will need the guts for the top cover but it is getting down there.

Link Posted: 2/25/2012 7:21:04 AM EDT
[#10]
I'm looking for a railed top cover.  Do you have a supplier for these?

Great project BTW!!  I love the 249.

101
Link Posted: 2/25/2012 8:41:58 AM EDT
[#11]
I see a few from time to time on Gunbroker in used condition, but US Machinegun Armory will have them at retail $620.00 I think.  I just bought the rest of my receiver parts from them, they are great folks.
Link Posted: 2/25/2012 11:10:38 PM EDT
[#12]
Thats going to be one cool SBR.
Link Posted: 3/1/2012 11:09:32 PM EDT
[#13]
Awesome.  I'd love to have a SAW.  Good luck on the project.
Link Posted: 3/1/2012 11:35:30 PM EDT
[#14]
This shall be tagged.
Link Posted: 3/2/2012 1:17:42 PM EDT
[#15]
Will you be going with striker or hammer fired?
Link Posted: 3/3/2012 12:35:52 PM EDT
[#16]
Most likely hammer fired.  USMGA has a proven design and the parts not any more expensive than regular FA parts.  The weld-up will start after I finish machining the channel.  I have to study my prints a little more as I will be leaving out alot of cuts need for the M249 MG and only using what I need for the design.
Link Posted: 3/16/2012 2:26:32 PM EDT
[Last Edit: rncbinc] [#17]
OK I have been working on converting the metric prints to english cad and I have this so far.







Note the lack of a cutout for the trigger housing group due to that SA part has not arrived so I could not measure to fit.  I may omit the OP Spring Guide notches at the rear of the receiver as I will not need them for SA version.
I have also left out the magazine feed on the advise that it is more trouble than it's worth.  The receiver channel I got was not bent to FN spec's but it will do.
Link Posted: 3/18/2012 10:32:36 AM EDT
[#18]
Here is a few more pictures of the parts and fitting process.  I was ready to start cutting the receiver channel today but the motor on the mill died after 12 years so I have to order a new one Monday.  Still waiting on more parts but it looks like it will weld up fine.



















Link Posted: 3/18/2012 7:41:32 PM EDT
[#19]
I am impressed by your skill and determination on this, definitely will be following this thread!
Link Posted: 3/19/2012 2:01:45 AM EDT
[#20]
You are awesome.

Seriously, what a cool project, best of luck.
Link Posted: 3/19/2012 8:57:06 AM EDT
[#21]
This is looking great
Link Posted: 3/19/2012 9:14:36 AM EDT
[#22]
Tagscribe

Looks awesome.
Link Posted: 3/19/2012 9:20:48 PM EDT
[#23]
Here is a few more pics...more parts! Sweet. Just  a rough layout to get an idea of the finished product.  The fire control group will be SA not the FA pictured, but you all get the idea.   All of the receiver parts have arrived.  New milling machine motor should be here Wed. so Thur or Friday is cutting time.  Top cover guts are still proving to be a pain to get...good things come to those who wait I guess. Nooooooooo I want my parts now!  Sorry, I am getting really excited about this build.  Realisticly it is still a few months from finished but it looks more like a gun than a pile o' parts now.



Link Posted: 3/19/2012 9:34:05 PM EDT
[#24]
Have you SBRd it yet or are you going to get a long barrel for it? I love this project, please keep the updates coming.
Link Posted: 3/19/2012 9:44:34 PM EDT
[#25]
I'm going to blind pin then spot weld the flash supressor on to get 16 1/4"  from the current barrel. I may register it later as a SBR  but I hate to pay another $200 tax when there is such an easy work around.  Plus all my other Class 3 paperwork took forever and a day to come back.  It would look cool with my 5.56 supressor attached too.  But that's a while down the road.
Link Posted: 3/20/2012 1:41:34 PM EDT
[#26]
suscribed to this, i love seeing builds like this.
Link Posted: 3/22/2012 11:39:23 PM EDT
[#27]
Great job! Just finishing up the same project. If I can help you with the semi parts, feel free to PM me.
Link Posted: 3/23/2012 12:21:24 AM EDT
[#28]
awesome cant wait to see more progress on this.
Link Posted: 3/23/2012 3:52:48 PM EDT
[#29]
Originally Posted By billphoto:
Great job! Just finishing up the same project. If I can help you with the semi parts, feel free to PM me.


Where are your pics!
Link Posted: 3/23/2012 6:50:47 PM EDT
[#30]
Email sent.  Thanks for taking the time to look at the list.
Link Posted: 3/23/2012 7:24:29 PM EDT
[#31]
Dont know how to tag... but i will bookmark!

Keep up the good work!
Link Posted: 3/23/2012 7:38:41 PM EDT
[#32]
That baby needs the KAC Accesory Rail and the railed top cover, so you can slap a good red dot to complete the look.



Tagged for furhter posts.
Link Posted: 3/24/2012 8:43:08 AM EDT
[#33]
I have that railed fore grip, but now railed top cover.  I may just add the rail myself if I can find some good stock material to work with.
Link Posted: 3/26/2012 12:11:19 AM EDT
[#34]
This is gonna be sick, I look forward to watching your progress!
Link Posted: 3/26/2012 6:18:45 PM EDT
[#35]
I got a little work done in the shop today.  The reciever was roughed in, the gas tube retaining spring recess was cut and I did some more dry fitting.  I expect more parts in next week.
I have to wait on the sear/trigger cut because the trigger pack is on order and I will need that part to measure to the cut-out.  I think I am ready for weld-up









Link Posted: 3/26/2012 7:03:47 PM EDT
[#36]
I wish I had friends like you.
Link Posted: 3/26/2012 7:14:24 PM EDT
[#37]
Did you decide on leaving off the magazine well? I'm very impressed, please keep us updated, such a cool project.
Link Posted: 3/26/2012 7:28:55 PM EDT
[#38]
Sweet! It's evolving!
Link Posted: 3/27/2012 12:38:03 AM EDT
[#39]
This is so full of win!
Link Posted: 3/27/2012 7:54:52 AM EDT
[#40]
Yes, I decided to leave off the magazine well.  I was told, by someone who builds them for a living, that it is more trouble than it is worth.  Plus that's a few less parts I need to buy.

I don't know if this will be helpful or not...but here is a list of things I have learned so far on this build.

1-Get a complete set of prints and the TM for the weapon before you start.  The prints are in Metric.  The TM has a complete parts list by group and part #'s are very important.
2-Buy the most complete parts set  get you can get, even if it cost a little more up front it will save you time and money trying to track down all those little springs, parts and peices.
3-Buy your channel, trunion, bridge and rails as a set from one person if you can.  All channels are not cut or bent to FN spec's and may need to be modified to fit.
4-If you do buy the channel seperate, get one that is a complete as possible, machining all the holes and cutouts is hard if you don't have the right equipment.
5-If you are doing a SAR, US Machinegun Armory has all the SA parts for a well tested, functional, closed-bolt, hammer fired system. Lots of support from them during this build.
6-Some parts need to be heat treated after machining. Your local machine shop may offer this service.
7-If your not going to register your weapon as a SBR, have the flash suppressor permanetly attached to the barrel by a professional gunsmith to ATF requirments.
8-Measure twice, cut once and don't rush.  I buggered up a perfectly good charging handle rail by not measuring properly before I started cutting.
Link Posted: 3/27/2012 8:03:24 AM EDT
[Last Edit: BM-ARM-DPMS-guns] [#41]
Exiting build. Good luck with all!

I really enjoy my semi-auto conversions: 1910 Maxim / MG42 / BAR / M60E4 / Bren Mk1 / SG43 / Madsen and soon a Breda.
Link Posted: 3/27/2012 12:06:58 PM EDT
[Last Edit: rncbinc] [#42]
Ok...more work done on the channel.  Finished the ejection port bend, I had to heat it up to get it pliable the I hammered it into the right shape and angle.  I left myself a little material to mill it back to FN spec's for clearance to the Op-Rod group.  Also cut the lower weld hole for the trunnion and the cut-out for the vehicle mount.  Note to self:  Wire wheels spin across a shop like angry little monsters when they jump out of the chuck  in your drill press.









Link Posted: 3/27/2012 1:38:02 PM EDT
[#43]
It's true, the magazine port really isn't worth the hassle. Looking good, this thread makes me miss my SAW.
Link Posted: 3/28/2012 11:48:41 PM EDT
[#44]
Ill give you $39 to make me one. Pleeeeaaase?

Nice work so far!
Link Posted: 3/29/2012 12:12:21 AM EDT
[#45]
Originally Posted By masakari:
Ill give you $39 to make me one. Pleeeeaaase?

Nice work so far!


I would like to know the actual projected cost of this.


(And I'll give you $40 for it)
Link Posted: 3/29/2012 9:53:19 AM EDT
[#46]
My first post has an updated cost for the project to date.  I can't account for the hours spent online looking for parts, that's the fun part, but I have less than 4 hours of actual machine shop time into it so far.  The weld up and fitting will be a few more so I figure a total of 8 hours of shop time at $50 per hour witll be around $400 I would pay myself.  Even adding that into my current total and cost of final finishing I should come in at $6,000  Considering they retail for 15K for SA I think that will work just fine for me.  I looked at the shrike upper for about the same as I am doing this build and decided it would be more fun to have clone MG.  Side note, if anyone needs their channel finished, shoot me a PM.  I have all the prints and machining fixtures now and would be happy to help out.
Link Posted: 3/31/2012 6:13:33 PM EDT
[#47]
Well the parts are off for heat treatment, then I am on stand-by till my trigger group gets in.  I will post more later.  May be a week or two.
Link Posted: 4/3/2012 11:03:22 AM EDT
[#48]
Amazing work.
Link Posted: 4/3/2012 7:18:11 PM EDT
[#49]
Originally Posted By squirrelslayer1:
Amazing work.


Indeed.  Very nice!  
Link Posted: 4/4/2012 3:09:42 AM EDT
[#50]
I wonder if it will bump fire when completed, and if a slidefire stock could be used...
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M249 SAR Project (Page 1 of 5)
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