Charging Handle Project

[josiahg52]

I've owned my M4 for some years now and tried a dozen different charging handles. I had settled on the FFT 1/2" steel handle but wanted something more like the original.  The goal was to weigh less than the original and function the same.

This is what I have so far:

It is a factory Benelli handle turned down to accept an aluminum sleeve.  The sleeve is a press fit on this specific one right now.  Currently, it weighs 0.03 ounces more than the original but I think that will be very easy to overcome.  It functions perfectly well manually cycling the bolt.  I have not performed any test firing.  I wanted to gather any input here before moving too much farther forward.

Specifications of factory part:
Weight: 0.41 ozs (11.8 grams)
OAL: 1.96" (49.8mm)
Spool length: 0.79" (19.9mm)
Larger spool diameters: 0.37" (9.5mm)
Smaller spool diameter: 0.26" (6.5mm)

Modified dimensions:
Weight: 0.44 ozs (12.6 grams)
OAL: 2.21" (56.2mm)
Spool length: 0.91" (23.0mm)
Larger spool diameters: 0.42"  (10.7mm)
Smaller spool diameter: 0.36" (9.2mm)

It is longer overall because the spool is located farther out on the shaft and it is longer itself.

I think the style suits the shotgun.

I think by more closely matching both of the larger diameters to each other on the modified piece, adding additional axial grooves, and perhaps modifying the radius on the outside and adding a small one on the inside or simply matching the outside shape, it will be very easy to get at or below the factory weight.

[selleugraj]

That's nice, you should do titanium next then dlc black.

[josiahg52]

Titanium was what I set out to use but aluminum is lighter so it allows for different shapes beyond a cylinder that's usually seen. As far as finish, there is a local shop that does DLC and anodizing but I haven't approached them for costs or anything like that. I think, once I am satisfied with the design (and look), I'd offer it to someone who can take it and really put it through its paces one or two weekends to actually determine if it's an upgrade.

1) Should the handle stick out as far as it does? This provides additional leverage and tgst along with the increase in volume do make it more comfortable and effective, BUT that does mean you have a throng that hangs farther out of the side that can get snagged.

2) Is the shape I'm going for the right idea?

3) Will people accept basic aluminum over titanium?

[CEBEP]

I tried to understand what you were trying to achieve but am not sure I’m following. If only to have a lighter charging handle then I just can’t understand what a few grans of weight difference would make.
 

If you want to do a DIY charging handle with your own design then it’s clear.

 

Since you already tried dozens of models, I may recommend looking at To i System charging handles. They have different charging models available, sport, tactical, long, short etc for Benelli M4 and are a company doing parts for competition shooters. So they know what they’re doing. My friend have 2 and is happy with them. Here is, that I assume, is the smallest model, it’s 15gr, not sure if it’s too heavy for you.

 

 

[josiahg52]

I want a slightly larger than factory handle that is as light or lighter than factory at ~12 grams. If weight weren't a concern, any of the ones I have now would be acceptable. Some weigh three times what the factory handle does. I also wanted to get away from the cylindrical ones that are offered the most.

[CEBEP]

20 hours ago, josiahg52 said:

I want a slightly larger than factory handle that is as light or lighter than factory at ~12 grams. If weight weren't a concern, any of the ones I have now would be acceptable. Some weigh three times what the factory handle does. I also wanted to get away from the cylindrical ones that are offered the most.

Check stock charging handle of new Benelli M4 T Pro. I think this is what you may be looking for. 

[josiahg52]

Here is the M4 T Pro:

Certainly looks different. That bolt release pad looks like when some were drilling and tapping the factory button for a 1911 oversized magazine release button, IIRC. I'll try and get one to see the exact differences and then probably just refine the three I'm working on now to close the project out. Thank you for the input thus far.

[josiahg52]

I'm going to refine the one pictured above to make it mimic the pattern of the factory handle a bit more. I'll also decrease the OAL a bit. The second one I'm working on is slightly larger but similar in shape so I think I'll work it to look more like the M4 T Pro handle and then get both finished in a matte black DLC.