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[ M16 4-Way Select Fire ] [ Gun Recoil ] [ Intro to Long Range Mil Dot Shooting ] [ QuickLOAD ] [ 300 BLK ] [ Leupold RX2800 ]
By Major Rob Robinette
Warning: You must have a BATFE Form 1 with tax stamp before you start to legally build a suppressor. National Firearms Act (NFA) rules apply and you can do hard prison time for violating the law.
The first step in manufacturing a suppressor is getting permission from the Bureau of Alcohol Tobacco Firearms and Explosives (BATFE) by filling out a Form 1 and sending in $200 for a tax stamp. It will take three months to a year to get the tax stamp so send it in early. You must wait to begin building your suppressor until you receive the tax stamp.
9mm Tavor X95 With Suppressor
1 3/4 inch diameter by 5 inch long suppressor. The 9mm Tavor uses a blow-back action so it functions without a suppressor 'booster'. It has an odd 1/2'x36tpi barrel thread.
My homemade .22 suppressors are Hollywood quiet--quieter than a pellet gun--but many people are surprised by how loud suppressed 9mm and 45 ACP are. It's not like in the movies where all you hear is brass hitting the floor. My 300 Blackout suppressor is very comparable to my Silencerco Osprey 45 commercial suppressor but they're much louder than a suppressed .22.
Something else Hollywood gets very wrong is the sound of a bullet striking flesh--it's loud. When hunting with a suppressed rifle the reduction in muzzle blast allows you to hear the bullet strike. A shot to an animal's chest with a subsonic 300 Blackout round sounds like a two-by-four body smack. Hollywood really does need to pick up on this for a little extra realism.
Here's a short high quality stereo mp3 recording I made of a suppressed 300 Blackout shot where you can hear the muzzle blast, bullet whizzing by and the target impact. It was a 100 yard shot with the microphone about 70 yards downrange. The impact is as loud as the muzzle blast. The bullet was a 220 grain Sierra MatchKing boat tail bullet.
Speaking of subsonic bullet flight noise, the US Army's Silencers: Principles and Evaluations report found that streamlined boat tail bullets were much quieter in flight than flat base bullets such as the 30-30 Winchester or pistol bullets.
I decided to go with an all aluminum monolithic baffle design for a 300 Blackout suppressor as my first suppressor build. 'Monolithic baffle' means the baffle is cut from a single piece of round bar. 300 Blackout uses standard .308 size bullets and has fast spin rifling to stabilize heavy subsonic bullets. It's very good at sending heavy 240 grain bullets at subsonic speeds downrange accurately. 300 Blackout can also be loaded for supersonic and makes an excellent home defense and hunting caliber.
If I were building a suppressor for .308 supersonic loads I would use at the very minimum, steel for the blast baffle (first baffle the bullet encounters). A single steel engine freeze plug can make an excellent supersonic rated blast baffle. They come in many different diameters. An all aluminum suppressor should only be used with subsonic ammunition. The fast moving gas from supersonic rounds will quickly wear away aluminum baffles. All 147gr 9mm and 230gr 45 ACP ammo are subsonic.
I have used the .30 cal suppressor pictured below on several .308 rifles using subsonic 175 to 220 grain Sierra MatchKing bullets and Trail Boss powder. Subsonic .308 loads are very mild and a thick aluminum blast baffle is fully adequate. A 1:10' twist .308 barrel will stabilize a 220gr bullet at 1050fps. A 1:12 twist .308 barrel will not stabilize subsonic bullets. Low velocity bullets spin slower than full speed rounds so a tighter twist is needed for heavy and slow subsonic rounds. Trail Boss pistol powder works well because it's fast burning for less muzzle blast and it's a low density powder that will fill more cartridge space for more consistent subsonic velocity.
JBM Ballistics Bullet Stability Calculator
Use this bullet stability calculator to see if your rifle/bullet combination will stabilize a subsonic bullet. A stability value of > 1 will be stable.
***A note about pistol suppressors: Most semi-auto pistols are recoil operated (locked breech) and need a spring mechanism to decouple the barrel and suppressor to allow the pistol to cycle. A spring and piston decoupler or 'booster' allows the barrel to move back and cycle the pistol without the suppressor initially moving with it. Because of this the non-booster suppressors on this page will not work with recoil operated pistols. Blow back pistols, like most .22 pistols, do not need a booster so the suppressors on this webpage will work with them. Rifles, of course, will also work with the suppressors shown on this webpage.
Pistol caliber carbine rifles are a great fit for homemade non-booster suppressors because they do not use pistol style locked breach operation. Also their heavy, large diameter bullets hit hard at subsonic velocity and their longer barrels allow fast burning pistol powder to completely burn for less muzzle blast. They make excellent home defense weapons for these reasons. I absolutely love my Tavor X95 bullpup in 9mm with a homemade suppressor but a 45 ACP carbine would add some stopping power.
I'm a big fan of holographic and red dot sights for subsonic weapons due to the typical short ranges used. Pistol iron sights are also a good match for subsonic shooting.
.22 Caliber Suppressor On Sig 1911-22
1 1/4 inch by 7 inch long suppressor. This pistol's blow back action has a fixed barrel so no suppressor 'booster' is required.
These are two of my favorite books on suppressors:
I used 1 1/2 inch outside diameter aluminum round bar for the 300BLK and 9mm baffles and 1 1/2 inch inside diameter aluminum round tube for the baffle covers. The specs on the aluminum round bar are: 1 1/2 inch diameter 6061 T6 aluminum round Stock # R3112 from www.metalsdepot.com. The 1 foot long bar only costs $17. The 300BLK suppressor is 8 inches long. The tubing for the baffle cover is 1 3/4 x .125 (1.75' diameter with .125' wall and 1.5' inside diameter) 6061 T6 round tube Stock # T3R134125. This size suppressor is what I recommend for all calibers except .22 or .17.
For my .22 caliber suppressors I use a 1 inch outside diameter 6061 T6 aluminum round Stock # R31 and 1 1/4 x .125 (1.25' diameter x .125' wall and 1' inside diameter) round tube Stock # T3R114125. I have built .22 suppressors at 6 and 7 inches long and prefer the extra suppression the 7 inch length gives. The extra length really helps quiet a short pistol barrel.
MetalsDepot.com Order
The first and third items are for a 1 1/4' diameter .22 suppressor, the second and fourth items are for a 1 3/4' diameter 300 Black suppressor. 1 foot long round bars are all that is needed to make a suppressor. Note how the outside diameter (OD) of the baffle matches the inside diameter (ID) of the tube.
You can also split the difference between these two size suppressors and use a 1 1/2' outside diameter x .125' wall x 1.25' inside diameter tube (stock # T3R112125) with a 1 1/4' diameter aluminum round bar (stock # R3114). This size suppressor will have to be longer than a 1 3/4' diameter suppressor for the same sound suppression but it will look sleeker.
To manufacture a monolithic baffle suppressor the basic steps are:
Start with a solid round metal bar to make the baffle
Cut the bar to length
Face both ends of the baffle on a lathe
Drill and tap one end of the baffle where the baffle will screw onto the threaded barrel
Drill the bullet path through the baffle
Drill/mill out the gas chambers in the baffle
Clean the bullet path with the bullet path drill bit
Cut the baffle cover tube to length
Face the ends of the baffle cover tube on the lathe
Finish the baffle cover tube on a lathe or simply polish it with steel wool
You may need to remove some material from the outside of the baffle so that it will fit inside the aluminum tube
Insert the completed baffle into the baffle cover tube and seal. If you have difficulty knocking the baffle into the cover tube with a plastic mallet then remove more metal from the outside of the baffle to slightly reduce its diameter. The seal can be a press fit, welded, epoxied, one or more small screws, or even duct tape. .22 suppressors work fine with a press fit but larger caliber's will need something to keep the outside tube from leaking gas and shifting position under fire. Two or three small screws around the end of the suppressor works well for this purpose.
The pictures below show three suppressors being manufactured, an 8' x 1 3/4' 300 Blackout, a 5' x 1 3/4' 9mm and 7' x 1 1/4' .22 caliber. I have Form 1's and tax stamps for all three.
I use a chop saw to cut the round bars and tubes. A vice and hack saw can also be used because facing the bars and tubes in a lathe will true them up.
Facing the Suppressor Baffle On the Lathe
Facing the suppressor baffle ensures a precision fit and alignment when the suppressor is screwed onto the rifle barrel. Face both ends of the baffle and tube. Facing the baffle and tube will also make it easier to mount them square in the lathe.
Drill the Barrel Thread Tap Hole
To prepare for tapping the barrel thread I drilled the thread end of the baffle. The depth of this hole isn't critical because it will lead into the large blast baffle but it needs to be deep enough to allow the suppressor to screw onto all the thread offered by your rifle barrel. Longer baffles will need to be supported on the lathe by a steady rest (shown holding the baffle at near end). The tail stock holds the drill bit stationary and in perfect alignment while the lathe spins the baffle.
Thread sizes are given by diameter and threads per inch or mm. '1/2x28' means 1/2 inch diameter and 28 threads per inch (tpi). 'M13x1LH' means 13mm diameter and 1 thread per mm left hand.
.22/.223/5.56 use a 1/2x28 tap and a 7/16 (.4375) inch drill bit.
The Steyr Aug uses a metric M13x1LH (13mm x 1 thread per mm left hand) and a 12mm drill bit.
H&K 5.56 uses a M15x1 and a 14mm drill bit.
Sig Sauer Mosquito and GSG Firefly use a 9mmx0.75 and an 8mm drill bit.
.308 and 300BLK use a 5/8x24 tap and 9/16 (.5625) inch drill bit.
6.5 Creedmoor, 6.5 Grendel and most other 6.5 & 6.8mm rifles use the .308 standard 5/8x24 tap and 9/16 (.5625) inch drill bit.
7.62x39 AK-47 uses a metric M14x1LH (left hand) and a 13mm drill bit.
9mm uses a 1/2x28 tap (same as .22 and 5.56) and a 7/16 (.4375) inch drill bit.
The Tavor 9mm uses 1/2x36 tap but still uses a 7/16' drill bit.
H&K and Sig 9mm (including MPX) use a M13.5x1LH (left hand) and a 12.5mm drill bit.
338 Laupa Some use the .308 standard 5/8x24 tap and a 9/16 (.5625) inch drill bit while others like the Ruger Precision Rifle use a 3/4x24 tap and a 11/16' drill bit.
.40 cal uses 9/16x24 and a 1/2' (.5') drill bit
H&K .40 uses a M14.5x1LH and a 13.5MM drill bit.
45 ACP uses a .578x28 (37/64x28) inch and a 17/32' (.53125') drill bit.
H&K 45 USP Tactical uses M16x1LH and a 15mm drill bit.
H&K Mark 23 Socom uses M16x1RH and a 15mm drill bit.
Optional Boring For the Tap
Boring the tap hole to the pre-tap size. This is not necessary if you have the correct size drill bit as listed above.
Tap the Baffle Thread
Tapping the baffle--Do not use lathe power to do this. I used the tailstock to simply hold the tap for perfect alignment with the bullet path. The tailstock is loose so it can be pushed by hand into the baffle. I turned the lathe chuck by hand to start the tap. I did the last half of the tap using a standard tap hand wrench so I could feel when the tap bottomed out. I used a 5/8x24 threads per inch (tpi) tap to match the thread on my 300 Blackout barrel.
Finish the Tap By Hand
Finish the tap by hand so you can feel the tap bottom out. This suppressor is for my Tavor X95 9mm bullpup rifle so the thread is an odd 1/2' x 36 threads per inch. Shorter suppressors like this can be worked on the lathe with only the lathe chuck holding the baffle (no steady rest needed).
Drilling the Bullet Path
You can flip the suppressor baffle around and drill from both ends to keep from having to use a long drill bit. The bullet path drill bit will be smaller than the thread hole--see below for bullet path drill bit sizes. The drill bit is held stationary by the tailstock and the lathe spins the baffle.
Using An Extra Long Bullet Path Drill Bit For Long Suppressors
Drilling the bullet path the full length of the suppressor baffle. Start the bullet path hole with a normal length drill bit for more precision then switch to a long bit when needed. I got the long 11/32' drill bit at Home Depot.
300BLK and .308 bullet diameter is .308 inch so use an 11/32' (.344') drill bit for the bullet path through the baffle.
.22 and .223, 5.56 and 224 Valkyrie bullet diameter is .224' so use a 1/4' (.250') drill bit. If your suppressor is longer than 7 inches you may want to go with a larger 9/32' (.281') drill bit for more clearance at the exit hole.
9mm bullet diameter is .355 so use 3/8 (.375') bullet path. If your suppressor is longer than 8 inches you may want to go with a larger 13/32' (.406') drill bit for more clearance at the exit hole.
.40 cal and 10mm bullet diameter is .40' so use a 7/16' (.4375') drill bit.
45 ACP bullet diameter is .451 so use a 1/2' (.500') drill bit.
These are my favorite books on the AR-15, M16 and M4:
Drill the Baffle Gas Chambers
Drilling the baffle chambers. Note the marked baffles to be milled out. I started with a drill bit then finished up with an end mill (below) to finalize the baffle chamber shapes. You must leave enough metal from the barrel end of the suppressor to the blast chamber (first chamber) to allow the suppressor to screw onto the entire length of thread on the end of your barrel. In other words, don't cut the blast baffle too close to the end of the suppressor.
Milling the Baffle Gas Chambers
Homemade Gun Silencers Suppressor Blueprints
Clean the Bullet Path
Cleaning up the bullet path after milling using the bullet path drill bit.
The Finished Baffle
The finished baffle. I had to turn the baffle in the lathe to remove about 15 thousandths from its diameter to make it fit easily into the tube. I intentionally left the baffle chambers odd shapes to disrupt the gas's path through the baffle. I now recommend heart shaped baffle chambers like in the .22 suppressor shown in the next section because of how well that shape worked in controlling the gas. I also recommend leaving much less metal between the chambers to make the gas chambers as large as possible and also make the suppressor lighter.
Welded Tube-to-Baffle Seal
I slid the completed baffle into the aluminum cover tube and welded both ends to seal the suppressor. It's now ready to be screwed onto a rifle, inspected for barrel alignment and test fired. Please forgive the crude welding, I'm an amateur aluminum welder. You'll need an AC TIG welder to do this kind of work. If I need to open the suppressor I can use the lathe to cut the welds to remove the tube cover. A sealed suppressor can be cleaned by soaking it in mineral spirits. If I were to do another 300BLK suppressor I would go with a press fit like the .22 suppressor shown below in the next section.
Mounted 300BLK Suppressor
The suppressor wrapped and installed on the 300 Blackout upper. The wrap helps reduce noise too.
Before test firing a suppressor you must mount it and do a bore sight inspection to verify the baffles and exit hole are lined up with the rifle bore. If the suppressor exit hole doesn't look perfectly centered don't fire the weapon because a baffle strike will destroy your suppressor. Remove all washers and lock nuts from the rifle muzzle because they can throw off the suppressor alignment. The best alignment usually comes from seating the suppressor tightly against the muzzle thread shoulder.
The BATFE requires you to inscribe or engrave the exterior tube of the suppressor with the information from the Form 1:
Serial #
Model #
Manufacturer (your name or trust name as shown on the Form 1)
A well made .22 suppressor really can be called a silencer because they are Hollywood quiet. Mount one of these on a Ruger 10/22 and you'll soon be looking for ways to quiet the action or lock the bolt closed. They're that quiet. I absolutely love shooting suppressed .22 and at 4 cents a round you can't beat the price-to-fun ratio.
Finished .22 Baffle
A .22 baffle made of 1 inch solid round aluminum bar. Note the large square blast baffle at the bottom and the heart shaped gas chambers. This suppressor worked out very well and is quieter than a commercial .22 suppressor I purchased later. The baffle is 7 inches long.
The author shooting suppressed subsonic .22LR from his Ruger Precision Rimfire. Long range subsonic 22LR is absolutely crazy fun to shoot.
For the suppressor barrel thread I used a 7/16 inch drill bit to drill the hole and then used a 1/2x28 tap.
.22 bullet diameter is .224' so I used a 1/4' (.250') drill bit to drill the bullet path through the baffle.
Baffle Ready For Insertion
The 1 inch diameter .22 baffle next to it's outer cover seal tube made from aluminum tube with a 1 inch inside diameter.
Completed .22 Suppressor
The .22 baffle inserted into the tube seal with a nice tight press fit. This thing is quieter than a pellet gun when used on a bolt action .22. Seriously.
Before test firing a suppressor you must mount it and do a bore sight inspection to verify the baffles and exit hole are lined up with the rifle bore. If the suppressor exit hole doesn't look perfectly centered don't fire the weapon because a baffle strike will destroy the suppressor. Remove all washers and lock nuts from the rifle muzzle because they can throw off suppressor alignment. The best alignment usually comes from seating the suppressor tightly against the muzzle thread shoulder.
The BATFE requires you to inscribe or engrave the exterior tube of the suppressor with the information from the Form 1:
Serial #
Model #
Manufacturer (your name or trust name as shown on the Form 1)
Silencer Plans Pdf
SBR 10/22 & Suppressor
This is a shorter 6 inch long by 1 1/4 inch .22 suppressor I made (with Form 1 tax stamp) mounted on my NFA registered Short Barreled Rifle Ruger 10/22 with a nice Keystone Sporting Arms Revolution Yukon Laminate Thumbhole Stock. I shortened the stock to fit the 8 inch barrel. This is a really great shooting suppressed .22 with the EOTech 510 holographic sight. Barrel is an 8 inch TacticalInc.com stainless Charger pistol barrel (Ruger Charger barrels fit the 10/22). Since a suppressed bullet only needs to accelerate to 1000 feet per second a short barrel like this works great. Anything longer is a waste for subsonic shooting. Another benefit of the 8 inch barrel is most standard velocity .22 ammo will be subsonic so I can use cheaper ammo. Standard velocity ammo also functions the action more reliably than subsonic ammo. I install a Volquartsen Target Hammer in all my 10/22s for a huge improvement in trigger pull and break. I also installed a JG Bolt Lock on this rifle to allow single action silence by flipping a lever. The bolt lock holds the bolt closed and keeps it from cycling to minimize noise. Your rifle must be registered as a short barreled rifle with a Form 1 and tax stamp to legally install a barrel shorter than 16 inches.
Ruger Precision Rimfire 22LR With All Aluminum Suppressor
Nothin's more fun than long range subsonic .22 gong ringing. Shooting from the rear upper deck and the family doesn't even notice.