AK series specific tools
Rivet builds
To do a rivet build you will need several tools and jigs to set the rivets. These tools can either be hand set tools or press set tools. You will need the following:
Short rivet tool
Long rivet tool
trigger guard rivet jig
Press set tools
If you have access to or are buying a shop press there are jigs and tools you can buy or make for setting the rivets. The short rivet tool can be a "Plinker" style jig or a set of modified bolt cutters. If you go with the "Plinker" style jig from AK-Builder it will also do the long rivets. These jigs are available from several suppliers:
http://www.ak-builder.com/ak/index.php They have the "Plinker" style jig and the trigger guard jig.
http://dpharms.com/ They have the trigger guard jig.
http://gunthings.com/ They have the long rivet jig.
These are just the suppliers I have done business with and there are many others who supply these items. You can also check the chat boards for tools for sale.
Hand set tools
To set the rivets by hand you will still need the tools and jigs but you will be able to make them yourself. The short rivets can be set using a modified bolt cutter. I prefer the 36" cutters since they have more metal to work with and they seem to hold up better. You can make these yourself using the angle grinder for around $20.00. They are also available in the Market section of most AK chat boards. This is what it looks like:
Remove the lower jaw from the cutter and lock it in the bench vise. Use the angle grinder to shape the jaw so the it will fit into the front of the trunnion all the way back to the rear rivet location. Go slowly with the grinding process. You do not want to change the heat treating on the jaw. Take a little off and let cool down and then take some more off. You want to end up with a 1/4" square at the end for setting the rivet. You will also need to make a bucking bar to protect the rivet head and insure that the rivet sets tight.
I made this from a piece of 1/4" scrap. You can make the rivet head detent with the Dremel or a 5/16" ball end mill.
To set the long rivets I modified a second set of 36" bolt cutters.
I did this modification using a 14" chop saw. Once I had them formed I made a rivet head detent in one jaw to form the new rivet head as it was set. I will have more details on how these are used in the "Building the receiver" section.
You can also set the long rivets by hand using a bucking plate, a hand punch and a hammer.
Using a piece of 1/4" flat stock you will locate and mark where the rear rivets go. Make a detent for each rivet head with the Dremel or a 5/16" ball end mill.
Using a piece of 3/8" round bar stock make a detent in one end to form the new rivet head. Clamp the receiver with the trunnion and rivets in place to your bench and use the punch and hammer to set the rivet and form the head. You can use this same process for the center support rivet by reversing the punch and making a flat head for the selector to move over. You can also use the long rivet jig from http://gunthings.com/ in this same fashion.
Next up is the trigger guard rivet jig. This jig is used as the bucking bar for riveting the trigger guard on the receiver. Start with the 1/4" x 1 1/2" x 6" piece of steel. Mark a center line length wise and drill a .375" hole 1.750" in from each end. Using the jig saw with the metal cutting blade make two cuts length wise from hole to hole. You will now have a slot 3" long and approximately .375" wide.
You will now need to finish the slot with files or the Dremel. Square the ends and make the slot only as wide as is needed for a tight fit. The front of the trigger guard is wider than the rest and will also need slight grooves for the mag release rivet to slide through. You can now make the rivet head detents using the Dremel or the 5/16" ball end mill. You can see how the trigger guard will sit in the jig. I will have more details on how these are used in the "Building the receiver" section.
Flat bending jig
If you are going to use a bendable flat you will need a bending jig. This is normally used with a shop press but I have seen them used with a hydraulic jack and solid frame. There are several suppliers for the bending jigs:
http://www.ak-builder.com/ak/index.php They have several options for this jig.
http://dpharms.com/ They offer the basic bending jig.
Again, these are only the suppliers I have used. These items are available form other sources or you can check the Market section on the chat boards for used ones for sale. You can also make your own using these plans:
http://www.quarterbore.com/images/555thjig_print.pdf
Spot welder modification
If you opt to use a spot welder to attach the lower rails you will need to modify the lower tong to fit into the receiver. This can be done with the angle grinder and hammer. You will also need to buy a tap and drill bit to reinstall the tip. Start by removing the lower tong and using the anvil on the bench vise flatten it out to a straight rod. Measure the tong so that it will be the same length as the upper tong when reinstalled. Using the angle grinder flatten out one end as shown and drill and tap it for the tip. Reinstall the tip and shape it as shown in the images.
Barrel press
This is an option for reinstalling the barrel if you do not have a shop press. It is very simple to make and works like a charm. All you will need is a 36" piece of 1/4" thread rod, a piece of 1/2" key stock, a 1/4" nut, some thin wall aluminum tubing and a 1/4" tension nut. I bought all of this at ACE hardware.
You will need to make the back locking bar from the 1/2" key stock with the grinder or Dremel. It then needs a 1/4-20 hole drilled and tapped for the draw rod.
Screw builds
To do a screw build you will need the following tools:
Tap Handle
1/4-20 taper tap
#7 drill bit
10-32 taper tap
#21 drill bits
8-32 taper tap
#29 drill bits
6-32 taper tap
#36 drill bit
Cutting oil
Allen wrenches to fit each screw size
I will have more details on how these are used in the "Building the receiver" and assembly sections.
Kit selection and 922(r) compliance
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