M16A1 Handguards

[HOOKED ON HISTORY]

A man after my own heart.
I just came in from 95 deg. F 100% humidity heat building a set of light brackets for a truck that I could have bought for $40.
Sometimes you just need a challenge.
I have contemplated your mission although never tried it. Perhaps build a supporting form with cardboard or something like it to the rough shape of the "tooth". Coat it with some type of release agent and build up with bedding compound or HB weld? File /dremmel to final shape?
That's as far as I got with my brainstorming.
P.S.
I should have bought the brackets.

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[usabaker]

Perhaps build a supporting form with cardboard or something like it to the rough shape of the "tooth". Coat it with some type of release agent and build up with bedding compound or HB weld? File /dremmel to final shape?

Mississippi, I remember those days even sort of miss them. I was stationed in Gulfport in 1977 ~ 1979 almost moved back, might of too except for a crazy woman that kept stalking me. Anyhow, Didn't think of Acraglas bedding, did think if the JB Weld. I have some silicone molding material I was thinking about making a mold off the good set and then set the mold in place in the set that needs restoration and use fiberglass, JB weld, or now Acraglas; not sure which will adhere better to the A1 plastic.

I just came in from 95 deg. F 100% humidity heat building a set of light brackets for a truck that I could have bought for $40

Why buy when you can make, there is something about making and fixing that overrides fast, easy and cost. So how did the brackets come out since you say ya should have bought them?

[ArizonaBeagle]

I also have a couple of hand guard sets that need a tooth or two replaced.
I was planning on using fiberglass cloth somewhat oversize and file/dremel to fit.
Just haven't gotten around to it yet.
I'll be curious to see what you end up doing with yours.

AZB

[HOOKED ON HISTORY]

Why buy when you can make, there is something about making and fixing that overrides fast, easy and cost. So how did the brackets come out since you say ya should have bought them?

Feeling better about the fabrication project now that I have cooled off. I really enjoy making / repairing things.
Keep us posted on what works as I have a couple of sets that could use some orthodontic repairs.
P.S.
Building a retro AR is great fun as well.