I'm running a GG&G scout rail/Aimpoint combo on a carbine and want to add a full rail cover to the top of my KAC RAS. None of the various sizes of KAC panels fit closely enough to make me happy, and I think I'll cut down a full length KAC panel to a custom fit. I know some manufacturer's panels can be custom cut by the user, but has anyone done this with a KAC panel? The material seems to be a glass-filled plastic....does it cut well, or does it chip? Anybody done this (if so, what worked)?

Thanks

KAC panels mill/cut beautifully with a Dremel.

I've been able to cut, mill, and shape them like plastic.

In the attached pic, you can see recessed milling under the PAQ paddle switch, and a recessed mill, to accomodate a flush strip of velcro. The panel under the PAQ unit (on top of the rail) has been cut short and rounded.

I liked KAC rail panels the best but at upwards of $20 a pop regardless of length I had to come up with a way to save some cash. $60+ for three panels was a bit much. I had an idea. What if I buy two full size panels, cut to length the panel for behind my weapons light and come up with an idea on how to utilize the scrap piece.

To secure the scrap piece to the underside of my HG’s I went to Lowes and purchased a rubber insert with a threaded metal sleeve. When a screw is inserted into the sleeve and tightened the rubber expands securing the rail cover to the holes running the length of the HG’s. An aluminum trim washer with Alumablack applied and a screw with a finish similar to parkerizing finished off the project perfectly!

This modified panel has never come loose and is rock solid! Heat from the barrel has not effected the rubber either.

cut and sand it smooth to match the factory ones.

Thanks, especially for the pix! I'll get the dremel to work.