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M249 SAR Project (Page 1 of 5)
Posted: 2/6/2012 10:42:05 AM EDT
[Last Edit: rncbinc][Edited]
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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 |
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.
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| 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. |
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. |
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.
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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.
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| 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. |
GIVE THEM NOTHING, BUT TAKE EVERYTHING!
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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. 
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Tennessee Squire
RIP SGT. Robert "Bobby" Wagner - 8/1/2004, Mosul Iraq.
"I really think people are trying to out-stupid each other." - D233
RIP SGT. Robert "Bobby" Wagner - 8/1/2004, Mosul Iraq.
"I really think people are trying to out-stupid each other." - D233
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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 
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Working so the other 50% doesnt have to!
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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. |
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.
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| 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. |
Collector of shoulder things that go up.
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M249 SAR Project (Page 1 of 5)
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