Do I send the form into the feds first, or try to get approval from the local sheriff first?
I have a couple of ideas. One is to just make up a bunch of baffels and chambers and stack them into a tube. The other is a precision cut set of baffels that will slide into a tube in two pieces with precision alignment, and can be easily removed for cleaning.You going monolith or individual chamber style? I'm also working on development of my own. Doing the research and creating CAD models for the past few months.
I have not made any baffles. However I work in a machine shop, and I can get these small flat wheels of aluminum with a hub and a hole thru the middle from work. By themselves they would not make good baffles, but if I set them at an angle and drill holes from the center hole all the way thru to the other side, I can divert off a great deal of gas at each baffel. The hub acts as a spacer to keep the whels apart, and I can add another spacer between the wheels if I think I need more space between the baffles. After the holes are drilled, I can turn the outer diameter of the wheels to the appropriate size for the tube. This arrangement is probably not as efficient as K baffles, but it is cheap, and keeps machining to a minamum as the wheels are only made from scrap parts that were not good enough to sell to the customer.You can get the ATF form 1 from here; ATF Online - Forms - Firearms You will also need form 5330.20; http://www.atf.gov/forms/download/atf-f-5330-20.pdf The AF form 1 is signed by the sheriff. Attach two passport sized photos to the form1 and send it in along with two fingerprint cards and a check for $200.
I make K or step cone baffles that are about .005" under tube ID. Ensure the tube is straight, end caps and baffles made square, and the silencer will align with the bore as long as the muzzle threads are cut straight.
You need to submit two copies of the Form 1, each printed on one piece of paper (front and back). If you print them on two pieces of paper they will get kicked back adding to your wait. One copy will be kept by the ATF for their records, the other will get a stamp and be returned to you. You only need one copy of the Certificate of Compliance (5330.20)You can get the ATF form 1 from here; ATF Online - Forms - Firearms You will also need form 5330.20; http://www.atf.gov/forms/download/atf-f-5330-20.pdf The AF form 1 is signed by the sheriff. Attach two passport sized photos to the form1 and send it in along with two fingerprint cards and a check for $200.