Quoted: I'm a FALAHOLIC and proud of it!
The best source for FAL info is www.falfiles.com.
Go there and look under Gunsmithing and Build It Yourself sections for anything and everything related to FAL construction.
It is somewhat more complicated or harder to build a FAL vs. a AR-15 but its worth it in the end.
As for tools you will need two or three specialized tools or if your handy you can make them yourself (like I did) adds to the fun of it.
Good kits are getting scarce so act quick after researching the FALFILES.
I would reccommend going with a Metric kit. I can personally vouch for the high quality of the DSA refinished G-1 metric kit. I received a like new barrel and every part was cleaned and freshly parkerized to nice grey/black finish. They also through in several new parts to replace any excessively worn original parts. Think about adding to the order the New Springs pack options. I believe my order ran less than $ 300 total.
For a receiver get a IMBEL Metric for about $199.
Remember these are 40 - 50 year firearms that have been well used, so expect to get what you pay for. A $99 TAPCO kit will be a ugly mess!
Enjoy !
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Major FALAHOLIC here too. What is going on with th FNFAL site? Seems abandoned these days. To chime in here the FAL is only harder to build because you can't get a barreled upper like you can an AR. The kits are drying up FAST. I have a refinished G1 kit from DSA too, can't say enough good about it but i think DSA is out.Unless you are handly with a sandblaster and can parkerize, stay away from all other G1 kits. They were sent to Turkey after the Germans were done with them and the Turks should be kicked out of NATO for how they kept their rifles. Best bet is an STG kit from DSA. If you have never done trigger work, buy the stg kit from DSA and the DSA US trigger parts, they will drop right in. Any other FN lowers I have done regardless of the trigger parts always needs fitting. Here is some solid FAL building advice and some common practices that are done and need to be avoided. DSA draws the receiver into the barrel which they swear by, I have seen a DSA receiver crack this way, which they replaced the same day. I do it this way too. Lots of guys will put the receiver in the wrench and vise and barrel it with a wrench on the barrel shoulder, to each his own. Ihave heard about some disturbing practices that you should NEVER do.
1. NEVER grind down a locking shoulder to headspcae, buy the right size LS. Entreprise condones this practice, stay away from them.
2. Heating up a muzzle brake with a mapp gas torch will cause soft spots on the brake, don't do it. Ask DSA to solder it on if you don't have access to an infusion machine.
3. Don't take the barrel shoulder down with a sanding disc, no one will ever convince me that this works correctly.
DSA receivers and barrels time PERFECT at 10:30 and they draw right up to TDC with ease.
Now you have the best rifle EVER made. The FAL will make you want to sell your AR's to get more FALS.