Specifications and later history on the Colt/Universal Industries 20 round mags:
The magazine was a precision component that had to be manufactured to exacting specifications. The magazine had to be able to feed cartridges into the M-16 firing chamber at the rate of 800 rounds per minute, and even the smallest irregularity in the feed lips of the magazine would cause a malfunction. Other linear dimensions were equally critical.
The most difficult part of the magazine to manufacture was the outer casing (also called the tube or box). Because light weight was always a goal, the tube was manufactured from aluminum instead of steel. Universal originally used T-O 6061 heat-treatable sheet aluminum, but found that the magazine tube distorted out of specification when this substance was heat treated. By trial and error, Universal found that aluminum with a magnesium content between 1.0% and 1.2% would hold its shape during heat treating, and found with difficulty an aluminum supplier able to deliver aluminum which consistently met this specification. Each shipment was inspected when it entered the Universal plant. The aluminum was then chemically analyzed to determine the magnesium content, and it was tested with a micrometer to insure a thickness of .04 in., ± .001.
The aluminum was then run through a series of 15 individual die-stamping operations. The dies used in these operations quickly wore to the point where they would no longer produce acceptable tubes. The dies thus required constant cleaning and sharpening. After the die-stamping operation, the tube was folded and formed.
The specifications for the magazine designated many dimensions as critical. The distance between the tube window and the magazine lips had to be held constant within .003 in.
The tube rib dimensions had to be held within .002 in. The width between the tube lips, where accuracy was essential to prevent malfunction, had to be held within .001 in.
However, even if each of the individual tolerances were successfully complied with, the finished magazine would often be unacceptable because of the error that resulted from the accumulated tolerances.
Thus, Universal was forced to tighten its operational tolerances beyond those called for by the specifications, and, as a result, some dies and equipment had to be changed.
After the tube was formed, it was vapor cleaned in preparation for welding. Each magazine required five spot welds, applied in an area 3/8 in. wide and 3 7/8 in. long.
Originally Universal subcontracted the welding, but because the subcontracting cost was so high (25¢ per weld) the company purchased its own welding machines and brought the welding in-house. Universal worked with its welding tip supplier to develop an electrode tip that could withstand the high temperatures necessary to weld aluminum. Universal also devised a staggered welding sequence to minimize shunting and began using steel mandrels to hold the tube in place.
Colt specified, during the early years of development, that one magazine in every five should be destruct-tested for weld defects.
The test required the seam of the magazine to be peeled back and the weld pried apart. A magazine so tested was destroyed and had to be sold as scrap; it was useless for any other purpose. By 1964, only about 1% of the welds so tested proved to be defective.
Heat treating the aluminum tube created several problems. The treatment was necessary to bring the metal to a proper state of hardness.
After an unsuccessful search for a subcontractor that could perform the treatment effectively, Universal built its own heat treating furnaces.
The heat treating had to be controlled within 25°. While temperatures too hot caused melting and distortion, temperatures too low failed to achieve the desired hardness.
The furnaces were constantly monitored to guard against these dangers.
Universal also developed special stainless steel mandrel racks that could, without themselves becoming distorted, brace the tube during heating. After some experimenting, Universal decided to form the tube slightly out of specification so that during the heat-treating process it would expand into specification. After treatment, the tube was artificially "aged" in an atmosphere created by Universal.
The next step in the manufacturing process, hardcoating, was subcontracted out. However,
Universal worked with the subcontractor to develop an effective hardcoating technique.
Universal also manufactured the base plate and the retainer spring of the magazine; the follower and the follower spring were subcontracted. Universal worked with both subcontractors to improve these components, supplying tooling and drawings.
Universal's quality control system for the entire magazine manufacturing operation was extensive.
Over 100 individual inspections occurred at various stages of the procedure. Every magazine produced was inspected, although not all received a complete inspection.
There can be little doubt of the complexity of the manufacturing process just described.
Colt's specifications were exacting, the tolerances tight.
The material was difficult to work with, but after both heat treatment and hardcoating, it emerged from the process significantly improved.
Sheets of raw aluminum, fresh from the mill, were transformed into stamped and folded tubes which were within .001 in. of each other.
The quality control necessary to insure regularity was extensive and demanding.
Universal achieved substantial reduction in costs during the review period by making numerous improvements in its manufacturing processes, particularly those for its major product, the aluminum magazine.
The two improvements in what particularly seemed to have increased its production dramatically were the introduction of a progressive die and a new method of testing welds.
Between 1964 and 1966 Universal designed and tested a progressive die which would consolidate a number of the tube-forming operations.
As finally put into effect, the die combined eight individual operations into a single, unitary process. Originally, the die was fed by hand, and about 20 magazine tubes a minute could be produced.
Later, an automatic feed was added, and between 60 and 70 tubes a minute were possible.
Fewer employees were required to operate the progressive die than had been required to operate the eight individual steps it replaced. It is not clear from the record exactly when the die went into operation.
It is fair to assume that, in accordance with the general sequence of events for production improvements, the progressive die did not replace the individual operations all at once, but underwent lengthy experimental use and adjustment. It is clear that sometime in 1966 the progressive die became fully operational.
The other big improvement to the production process was the introduction of a compression weld tester.
Previous to this improvement, the Colt specifications required the destruct-testing of 20% of all the magazines produced, a very costly and wasteful procedure.
In 1966 Universal replaced the destruct test with a compression test, in which a specially designed machine subjected each weld to 100 lbs. of lateral pressure.
As a result, all magazines produced by Universal could be tested without waste and only those tubes which would in any case have been rejected, i. e., the faulty ones, would then be destroyed.
Although to a lesser extent, other production improvements during the review years also increased efficiency by reducing costs. In 1966 Universal adapted a milk refrigeration unit for use with its welding machines. By improving the cooling of the welding tip, the unit reduced spitting, eliminated a cleaning step, and speeded up the tip cooling time. Also in 1966, Universal installed stainless steel mandrel racks to reduce wear of the mandrels used in the heat-treating process. Universal and its lubricating subcontractor jointly developed a special lubricating material which decreased the number of magazines rejected for poor lubrication. Air gauges, to measure several magazine dimensions simultaneously and thus speeded up the inspection process, were added to the production line in 1966 and 1967. A Barcol tester was installed to test the hardness of each magazine. Special aging tunnels were built to reduce the time each magazine had to be aged. Other processes for manufacturing various components were also improved, specifically, Colt and Universal jointly re-engineered the gas tube assembly while Universal, on its own, eliminated the brazing step previously required on the ejection port cover.
Adventure Line, Inc., a Kansas corporation which began in 1970 to manufacture the M-16 magazine under the US Government obtained TDP.
In that year, after the Government had acquired the proprietary rights to the M-16 and its components, Adventure Line received a contract for 2.4 million magazines, to be shipped to Colt as GFP.
Using a data package provided by the United States Army Weapons Command and presumably based heavily upon Universal's manufacturing experience, Adventure Line instituted a production line that resembled Universal's in most respects.
Colt tested the Adventure Line magazines it received and found several problems with them, problems which continued almost until the end of the Adventure Line manufacturing history.
Several entire shipments of the magazines had to be reworked to correct dimensional aberrations, poor lubrication, and improper heat treatment.
As a result of the problems encountered by Adventure Line, Colt refused further magazines and shifted to Okay Industries, Inc., as their supplier for the components.
Okay Industries is owned and operated by Mr. Edward Okay, who had served as the production manager for Universal during the review periods. Okay is still one of Colt's current subcontractors.