Test fitting some new parts.    Well regarded upper and charging handle.


The new charging handle is super tight.   I need to wiggle it into the channel.   Cycling it requires much force.    It reads .01 thicker than other charging handle of the same make.

This is without any bolt carrier.  Just the upper and the handle.   It doe not drop in.   I have to force it in after lining up the nubs.

It is easy to assume the coating is a lil thicker on the new handle.  It's like the width of the front part of the charging handle is the same as the wide of the channel it rides in the upper.

Do i sand it down a teeny bit, lube it, and cycle it in?  or do I send it back ?


Other charging handles from the same maker bought a few years earlier work fine.  

wish the upper and lower fit this tight.....



Thanks all.

If you need it right now,  gotta have it,  then modify.  If you have time send it back.  It's easier for us to see others challenges without being emotionally involved.  i.e.  I get nutty over the small things sometimes.  Rifles must be maintained whether we like it or not.  Rust never quits.

Is your gas tube installed? I had an LMT (everyone makes mistakes) factory upper where the gas tube was mis-aligned giving the same problem you are experiencing. If it is a stripped upper, do your other charging handles fit?

NO.   This is bare upper and charging handle.   It is immediately apparent as the section of ch before those allignment tabs is as widenasnthe channel of the upper receiver.   It wont even drop in.  It needs to be forced.

 bfg:  Scrap the defective part and buy a proper charge handle.  Personally, I like BCM's Gunfighter models the best, they fit just fine in any mil-spec upper. Cost is about $35.  - CW

I had the same problem with the same brand (by the sounds of it). I just gently forced it into place and started using it and it loosened up quite quickly. To my surprise there wasn't any wear on it that showed bare metal

I wouldn't modify it since it's a pretty pricey piece of aluminum. Just use it.



By the sounds of it I'm not sure this will help unless the one he got was out of spec

Thanks all.

If you have more than one AR see if it works in a different upper, if so just switch them.

Definetly try using a different charging handle.  My Noveske upper with raptor fit way too tight, but i swapped it with a different raptor from another gun and now both work perfectly.  Tolerance stacking.  If charging handle is on the top side of the tolerance range and the upper is on the small side, things may not fit correctly.

It is only two parts, the tolerances are there so things can be at the min and max and still work.  Something is out of tolerance but it isn't a super high stress critical thing to make too big of a stink over.

This new CH  wont work in 3 different uppers.

All of my other CH work in the other uppers


Its def this new CH and it is going back with the very much appreciated help
Of the manufacturer.

Im glad i didnt get impatient and start sanding.

Jray is right.  Doesn't matter that it's only two parts.  I've run into this before on a bolt and bolt carrier.  Both parts were from very reputable companies.  Milspec parts usually fall somewhere in the middle of allowable tolerances.  Some of the better companies manufacture parts with tighter tolerances.  That's when you run into tolerance stacking.  I'd be willing to bet swapping the charging handle out with another will solve the problem.

OK I know this is not your problem but fore others we had one with simler problem turnd out the shaft was twisted

Who is the well regarded company?? I have several new charge handles in my spare parts which were recent purchases and am interested in which one you purchased??

It's not about brand.  I had to take sandpaper to my $90 Geissele to fit a spikes upper and it functions fine.  Sand it enough to cycle half ass smooth like then the rest will wear in.