Since 1934, Congress has limited the legal length of a regular rifle barrel to 16 inches. However, there is a caveat in the law that allows a barrel to be shorter if you permanently affix it to a muzzle device through welding or soldering. Your favorite place to buy ammo online has a step-by-step walkthrough for you to pin and weld your own muzzle break.
This project is relatively easy as long as you follow these steps and have access and knowledge to using a welding machine.
Step 1: Choose Your Muzzle Device
When picking your muzzle device you want to keep both rail and barrel length in mind. If you plan to use a muzzle brake, make sure the one you pick meets or exceeds the 16-inch mark and clears your rail. You can also use other muzzle devices like flash cans and suppressors that direct the blast upward or forward.
Step 2: Drill The Hole
There are a variety of tools you can use, but we recommend the combination of a Dremel tool and power drill. Drill the hole prior to the installation of the muzzle device, it will make it much easier to work with the brake. This will also allow you to know precisely when you have drilled far enough. The pin you choose does not have to match perfectly, however, it should be large enough for the pin to fit yet small enough to keep it upright.
Step 3: Measure & Cut The Pin
You can use the end of a steel punch or similar tool for your pin. Drop the punch into the hole, mark the correct length, and cut it with your Dremel tool.
Step 4: Pin Installation
The pin needs to be snugly seated into the barrel threads so the brake will not twist when the weld covers the pin. Next, cut a small indent into the threads being sure not to get carried away by drilling all the way through. Once you have a small hole, tap the pin into it until secure.
Step 5: Weld The Pin Securely
You may need to scrape some of the paint from the muzzle device for a good connection when welding the pin. There will likely lead to the creation of a small bubble at the point of the weld. You can always file the bubble down and paint over it to make the weld almost invisible and match your brake and barrel.
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