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.
A suppressor can become hot enough to burn you if you shoot enough rounds through it. I laid my rifle down on a tarp and melted it to the suppressor so be aware of the heat.
Be sure and check the security of the suppressor for tightness with a gloved hand between shooting breaks. They can loosen over time and cause a baffle strike.
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)
Manufacturer's city & state
I used a Dremmel tool with a fine bit to engrave the suppressor information.

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.

Another Ruger 10/22 with Suppressor

Gun Silencer Plans Pdf

The .22 suppressor installed on my Ruger 10/22 with threaded 16' bull barrel. This rifle also has a Volquartsen Target Hammer and JG Bolt Lock.

Suppressor On Sig 1911-22

Since this .22 pistol uses blow back to function it will cycle with this no-booster suppressor mounted. Most semi-auto pistols are recoil operated and require a spring & piston 'booster' to decouple the suppressor from the barrel to function. A pistol with its short barrel is typically louder than a rifle of the same caliber so I run my longer 7' suppressor on pistols.

If you have a BATFE Form 1 and tax stamp you can legally build a suppressor using ebay 'flashlight' and 'filter' suppressors. You typically buy an aluminum threaded tube with two end caps. One end cap is threaded to screw onto the barrel muzzle. The other cap will either have a hole pre-drilled or be solid and ready for you to drill to the bullet path diameter. There are even lightweight titanium flashlight and filter tubes available on ebay. Complete suppressor kits are now on walmart.com (online only). The kits include the aluminum tube, threaded end cap, 'filter cup' baffles, spacer and end cap. Just drill the cups and end cap and you're done. The spacer creates the 'blast chamber' at the barrel end of the suppressor. Search for '1/2-28 filter' or '5/8-24 filter'. It's super easy to complete these kits but you can still do hard prison time if you don't have a Form 1 and tax stamp.

You can purchase 'C Cell Maglite' tubes that have a 1' inside diameter and can be purchased with a pre-threaded 1/2x28 end cap. These work well as 22LR suppressors. An ebay search for 'C Cell tube 1/2x28' or 'C Cell storage cups' or 'C Cell filter cups' will work. Dorman 555-097 steel freeze plugs are 1' in diameter and should fit.

C Cell Tube

Gun Silencers For Sale

One end cap is threaded for 22LR at 1/2x28.

There are also 'D Cell Maglite' tubes that are suitable for up to 308 Winchester (subsonic only) which can be purchased with many different barrel threads. For 308 or 300 Blackout you need a 5/8x24 thread. An ebay search of 'D Cell tube' or 'D Cell solvent trap' or 'D Cell storage cups' or 'D Cell filter cups' will work. I have also seen D cell Maglite M baffles referred to as 'D Cell hiking stick storage cups'. The tubes have a 1.350' inside diameter. NAPA Sealed Power SEP 381-3179 steel freeze plugs fit.

The larger diameter NAPA 4003 and WIX 24003 filters can be purchased with various barrel threads. An ebay search of '4003 filter 5/8x24' or '4003 filter cups' will find them. They're probably good only up to 308 Winchester but I've never tried a more powerful cartridge so I'm not sure. These filters have a 9' internal length. The inside diameter is either 1.8 or 1.75'. Real NAPA or WIX filters have a 1.8' inside diameter. Some of the ebay clone filters have an inside diameter of 1.75' so verify what you have before you order freeze plugs or filter cups. The Dorman 555-098 freeze plug is 1.77'x.44' and will fit in the real NAPA or WIX 1.8' filters. The Dorman 555-034 freeze plug is 1.75' in diameter and .43' thick and fit well in the 1.75' clone filters.

4003 Filter

This filter comes with an end cap threaded for 308 or 300 Blackout at 5/8x24.

To build a flashlight or filter suppressor you may need to make baffles. Dorman steel automotive freeze plugs can be formed into baffles with some work and the cost is low at about 80 cents each. Call ahead and most auto parts stores can get you a box of 10 overnight. With a lathe you can spin the plugs and center drill a 3/16' hole. Drill from the cupped end so the concave shape will keep the drill bit centered. Then place the plug over a wrench socket that fits and use a large punch and hammer to enlarge the hole to the desired bullet path size. As you enlarge the hole the punch will also bend the plug into the desired 'M' shape to make the baffle more efficient. The baffle will stick to the punch but you can tap alternating sides of the baffle with your hammer to knock it free. Use a bullet path size drill bit to verify the hole size as you enlarge the hole with the punch.

Forming a Freeze Plug Into a Baffle

Freeze plug is draped over a socket and a large punch is driven through the pre-drilled center hole. As you enlarge the hole, check its size occasionally with a bullet path sized drill bit.

I recommend putting four 3/16' holes around the bullet path hole in the first baffle (blast baffle). These holes allow some of the very high pressure blast wave to pass through and bleed some of the wave's energy.

Freeze Plug M Baffle

The notch in the bullet path hole keeps the gas from shooting straight down the center of the suppressor.

You can also purchase 'flashlight storage cups' or 'filter cups' that come in the form of an M baffle and work extremely well but they cost much more than freeze plugs. They come in C cell, D cell and 4003 filter sizes. You just have to drill the bullet path holes into the M baffles, notch the hole and slide them into the tube. There are even storage cups made of steel which will hold up better than aluminum to supersonic rounds.

D Cell Storage Cup M Baffle

Just drill the bullet path hole and add a notch. I like to drill a hole about half the size needed to clear the bullet then use a punch to enlarge the hole to final size. The punch will push metal outward to form a sharp edge to catch gas. They come in C & D cell and 4003 filter sizes. C size works well for 22LR. D is big enough for 9mm and similar size rounds and 4003 is good for 308 Winchester.

A filter or flashlight spring can be used as a spacer to form the blast chamber area (first chamber the rifle gasses encounter). You can also cut aluminum tubing to form spacers to separate the baffles or you can simply fill the tube with baffles but that does add weight when using steel freeze plugs. Mixing freeze plug and M baffles can also work very well for sound suppression. If you plan to shoot supersonic rounds greater than 22LR I recommend a steel blast baffle (first baffle). You can add one steel freeze plug blast baffle to a suppressor full of aluminum storage cup M baffles to ensure longevity.

When drilling the bullet path holes in the baffles it's a good idea to elongate the hole in one direction. This sends the moving gasses off to the side to strike the next baffle wall instead of just shooting straight down the center of the baffles. This is a common feature of commercial suppressor baffles. A 1/4' rat tail (round) metal file works great for this. For aluminum baffles you can use a 1/4' drill bit to elongate the hole.

Note how the skirt hole is opposite the entrance slot in this XCaliber Genesis suppressor M baffle. Hot gasses entering the slot push the main gas stream into the skirt hole to trap it between the baffle and suppressor wall. The Genesis is a very quiet .22 suppressor.

WARNING: Just because these Maglite and filter suppressors are easy to make doesn't decrease the severity of penalty for illegal possession. You can do hard prison time if you don't have a Form 1 and tax stamp for a suppressor.

Other Suppressor Design Tweaks

I recommend putting three or four 3/16' holes around the bullet path hole in the first baffle (blast baffle). These holes allow some of the very high pressure blast wave to pass through and bleed some of the wave's energy. This is a common feature in commercial suppressors.

You can make a suppressor quieter by putting a few drops of water or oil into the suppressor and it'll really reduce first round pop which is caused by cold dense air inside the suppressor. The downside is the liquid will mix with powder residue and stick to the suppressor interior and hasten the need for cleaning.

Placing a rubber washer between each baffle (freeze plug or storage cup) and between the last baffle and exit hole should help attenuate internal noise caused by reflection, vibration and resonance. Lowe's and Home Depot sell rubber washers in a variety of sizes.

Some silencers of the past used felt washers between the last baffle and the exit hole to absorb the diminished shock wave.

Gun Silencer Laws By State

Another technique of old was placing steel wool in the gas chambers but testing seems to confirm this isn't worth the trouble.

A thick piece of rubber sheet can be placed between the last baffle and exit hole to form a 'wipe'. Cut an 'X' slit for the bullet to pass. The rubber will slow the exit of gas from the suppressor exit hole but may reduce accuracy.

I highly recommend you put a little anti-seize compound on the tube and end cap threads to make disassembly easier.

To remove stuck baffles for cleaning a socket on an extension can be used to drive them out.

Don't forget that you must engrave your Form 1 information on the exterior tube of the suppressor.

Getting factory installed flash hiders and muzzle brakes off can be a pain in the butt without the right tools.

The standard wrench size for AR flash hiders is 3/4 inch but not all are standard.

For right-hand threaded devices, when looking down the barrel you turn the device counter-clockwise (left) to remove and clockwise (right) to tighten. Righty-tighty, lefty-loosey. Left-hand threaded devices will go the opposite directions.

The first thing I try is simply holding the rifle receiver between my knees and use a long 3/4' wrench on the flash hider and tap the wrench lightly with a metal hammer. About half the time this is all that's required to break the flash hider loose.

Many muzzle devices have high temperature thread locker like Loctite Red on their threads. If you find a really stubborn flash hider it probably has high temp thread locker on it. Applying a torch to the muzzle device (not the barrel) until cherry red will release the thread lock and allow removal but be advised using a torch may mar the finish of the muzzle device. Be cautious of the hot barrel and flash hider.

If you plan to do a lot of AR flash hider/muzzle brake/suppressor work I highly recommend the $83 Geissele Automatics Reaction Rod. You put the Reaction Rod in a vice then slide the AR upper on the rod. The rod is the same diameter as an AR bolt so it fits snugly. The bar has lugs that lock into the barrel lugs to keep the barrel from turning. This holds the barrel securely while you torque on muzzle devices so only the barrel is torqued and not the upper receiver.

Geissele Automatics Reaction Rod

AR upper on Reaction Rod.

I do not recommend using a standard AR upper vice block to remove muzzle devices because you can damage the upper receiver and/or gas tube.

For non-AR rifles these aluminum barrel vice jaws along with leather jaw pads work great to hold the barrel fast without damage or marring. I use this method on my hunting rifles and Tavor bullpups.

Aluminum Barrel Vice & Leather Inserts

If you have easy access to the barrel then aluminum and leather vice inserts will hold the barrel fast for easy muzzle device work with no barrel marring. The Tavor user manual shows how to remove the front shroud for barrel access. This 5.56mm Tavor X95 has standard 1/2'x28 right-hand muzzle thread. The flash hider was locked into position using a 3/4' lock nut. The 9mm Tavor X95 has an odd 1/2'x36 right-hand thread. The 300 Blackout Tavor X95 uses standard 30 cal 5/8x24 right-hand thread.

You can use an impact driver with a 3/4' crowfoot wrench (3/8' drive) and extension to help remove stubborn flash hiders. Place the extension on the impact driver then put the crowfoot wrench on the extension and place it on the flash hider's 3/4' flat side. Use a gloved hand to help keep the crowfoot on the flash hider and take your time using short impact bursts. I've done this but I nicked the barrel so I don't recommend it except as a last resort. Painters tape then several layers of duct tape on the barrel can offer some protection.

3/4 Inch Crowfoot Wrench

This wrench plus a short 3/8' drive extension on your impact wrench can help break loose stuck flash hiders.

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 directly against the muzzle thread shoulder.

Cartridge

Diameter Inch

MM

Other Cartridges With Same Bullet

.22LR

.222

5.64

.223 & 5.56

.224

5.7

(I know it's called 5.56 but it's not) 224 Valkyrie

.243 & 6mm

.243

6.17

6mm Creedmoor

25-20 & 257 Roberts

.257

6.53

6.5mm & 264WM

.264

6.7

6.5 Creedmoor, Grendel, Carcano, Japanese, 264 Win Mag

270 Win

.277

7.04

6.8 SPC

280 Rem

.284

7.21

7mm-08 Rem, 284 Win, 7mm x57 Mauser

308 Win & 7.62

.308

7.82

I know it's called 7.62 but it's not. 7.5mm Swiss (303 Savage is .311)

7.62x39.3127.92AK-47, SKS

32 ACP

.312

7.93

(32-40 is .324)

8mm, 325 WSM

.323

8.2

8mm x 57, 8mm Rem Mag, 325 Win Short Mag

338 Laupa Mag

.338

8.59

340 Wby Mag, 338 Win Mag

375 H&H Mag

.375

9.53

380 Auto

.355

9.02

(9mm Short, should be called 355 Auto)

9mm & 357 Sig

.355

9.02

9mm Parabellum, 9mmx19,

38 Special

.359

9.12

357 Mag (should be called 36 Special)

40 S&W & 10mm

.400

10.16

(40 S&W = 10mm Short)

416 Rigby

.416

10.57

44-40 Win

.428

10.87

44 Mag

.430

10.92

45 ACP

.451

11.46

45-70

.458

11.63

458 Win Mag, 450 Marlin, 460 Wby Mag

470 Nitro Express

.475

12.07

500 S&W Mag

.500

12.7

50 BMG

.510

12.95

50 Alaskan

Long slide Glock G41 MOS (modular optic system) 45 ACP with Osprey 45 suppressor, Burris micro red dot sight, Tru-Glow tall see-over-the-suppressor co-witness night sights and combo flashlight/green laser. The pistol is held to the bed rail by a plastic covered gun magnet. A suppressed weapon is ideal for home defense because firing an unsupressed weapon inside your home without hearing protection will freakin' hurt. 45 ACP 230gr hollow point ammo is subsonic--you don't need to buy expensive 'subsonic' ammo.

Warning: You must have a BATFE Form 1 with tax stamp before you begin to legally build a suppressor. National Firearms Act (NFA) rules apply and you can do hard prison time for violating the law.

By Major Rob Robinette

US Army and Air Force (Retired)

Major Robinette was a Battalion Marksmanship Champion, Squadron Rifle Team Captain and Range Officer. Rob also spent 10 years as a federal law enforcement officer. He holds a Federal Firearms License and is the CEO of Nolichucky Guns. He enjoys all forms of rifle and pistol use.

Ruger Precision Rimfire with M-LOK Arca-Swiss plate clamped into LeoFoto LH-55 ball head and heavy duty tripod.

Leupold RX2800