Finally getting around to building my jig, but have one remaining question... obviously the female part of the jig needs to be at least 1.25" + flat thickness*2, but I'm assuming it needs to be slightly oversize in order to get the bent flat out, plus compensate for any variantion in flat thickness... So, what are you guys using?   How much clearance is too much?

Thanks,
Rocko

On the jig I built it has .010 clearance. The tapco flats I measured were all the same thickness so I didn't worry about variations in thickness.
Once it is pressd into the die I need to tap it back out with a hammer.

Quoted: Finally getting around to building my jig, but have one remaining question... obviously the female part of the jig needs to be at least 1.25" + flat thickness*2, but I'm assuming it needs to be slightly oversize in order to get the bent flat out, plus compensate for any variantion in flat thickness... So, what are you guys using?   How much clearance is too much? Thanks, Rocko

Rocko...  are you working on these as well?  Can we get together as I have way overspent on my various tools already and I have been reading the various posts and info on building AKs and the list of things I need to buy or build is greater than I can do!

I am planning to get one of my FALs done this weekend (still need receivers for the kits I got from you)as well as a screw-built AMD-65 AK pistol and perhaps my second AMD-65 as a screw built.  I also need to try to finish the 80% AR-15 lowers as I really wanted my home built ARs (I am working on 3)done for a 10-year after the ban memorial!