Colt Triangle Cut Charging Handle Reweld
by edwin247

A helpful "HOW TO" for welding a Chopped/Torch Cut Triangle Charging Handle
Using a small punch remove the roll pin. Remove the pin from the opposite side from which it was inserted because these pins are very small and when they were originally inserted the pins were slightly flattened.
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Removing the roll pin from the Triangle Charging Handle.
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Both charging handles disassembled and ready for fitting.
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Cut the Triangle Charging Handle to the left of the deformed material.
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Another view of the cutting operation
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Triangle Charging Handle in the Jig ready for machining straight.
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Using a 1/4" Endmill machine the end of the cut section to manufacture a clean end.Set zero for the X-axis.
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Move over in the negative X direction 0.250"Mark the approximate cut point for replacement end of the new/used charging handle.
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Cut to the left of your previous mark.
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Machine a clean edge on the new charging handle end.
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Bead blast 0.375" of the anodizing off both charging handle pieces.
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A view of five charging handles prepared for welding.Make sure you bevel the edges of both pieces to insure a full penetration weld.
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Preheat the jig and charging handle to 350 degrees F.I used an old electric frying pan.
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Preheated Charging Handle and Jig.Two lengths of 0.063" diameter aluminum welding wire.0.063" diameter electrode.
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Four welded Triangle Charging Handles.
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I ran out of time today to complete the machining to remove the extra welding material

More information to follow!!!