Guide on Making a Kar98 Springer

[Sgt_Tom]

OK,
So I am working on a guide on how to convert a JG BAR-10 to a Kar98 using a Dboys Kar98.

Part I: Tools of the trade

First up is the Dremel tool, the ultimate airsoft conversion tool. If you don't have on get one it will make this go a lot faster.

You'll also need various attachments for it.


A Drill you need these for a few things and there just something every man should have ;D


Sandpaper will be used for sanding off paint and smoothing metal off after rough grinding and such. Get different kinds ranging from heavy grit to light grit.


A few rasps are very useful when you want to do heavier sanding then sandpaper and lighter sanding then a dremel.


A benchgrinder is really useful for heavy sanding, stuff that is even tough for the dremel to handle.


A hacksaw, everyone needs one of these. Good when your tired of using electric stuff.

[Sgt_Tom]

Ok now for the actual guide.
I will be uploading how to do different things over a bit of time.
Today we'll show you how to do the Kar98 Bolt Handle.


Parts needed
The PVC tube shown is a half inch one.


Ok so here is the bolt


Now take it apart.


Here's the parts you need to keep.



Now that you have the bolt strip down, cut it, like below.


Next step is we need to get the metal stick thing to fit inside the hole in the saftey switch mount thing.


How do we do this? Simple sand it down till it fits. It should look like this in the end.

The deep scratches in the metal were made so the glue when it is applied will stick better.

Next step is we need a spacer. I used a PVC tube I had laying around. Its the only thing I could find that would fit decently.



Done! Well with cutting the PVC tube that is.

Now we wrap the PVC spacer with tape so the bolt handle fits snug around it without wobbling. Don't make it too tight just enough so there is no wobble.


Now to put it together

Now put the bolt on.

Now put the spacer in.

Now put the end on.


Now for the last step.
Ok so you have the bolt assembled now what?
Buy some epoxy, I recommend JB Weld.
Mix it, make sure to pour the same amounts of each. You won't need too much.
*I highly suggest using a screw to hold this together instead of epoxy. Epoxy isn't as strong and doesn't allow you to take it apart.*

i252.photobucket.com/albums/hh11/Fighten3rd/Kar98%20Conversion%20Pictures/DSC06625.jpg
[/img]
Put some inside the hole here. You need very little, don't put too much on or it will leak out the sides and make a mess.

Now put it back together.

Make sure its lined up like in this picture below.

Now let it dry for 15 hours.

Lastly buy a screw from the hardware store. Take the bolt with you to make sure it fits right and all.

I had one lying around.

Now just screw it in the back,

and done.

And that is the simplest way to attach a bolt handle and it works very very well too, better then some more complicated ways.

[cfg123]

Wow! Great guide so far. Might actually try this.

[Sgt_Tom]

Yea I'll try to get more up as soon as possible. This thread will be pretty big by the time I am done lol.

[oberst42]

whats the diameter on the PVC spacer?

[Feodor]

wow, excellent guide. makes me almost sad im not a german I might do a bolt mod like this for my Mosin, but instead make a copy of the mp001 bolt handle, modify it to a straight mosin bolt, and cast a new one in pewter. i cant think of a better way to do it than that, im just glad my grandpa has the know how to do it. anyway, great tutorial, cant wait to see more.

[Sgt_Tom]

Thanks Feodor, good luck with your mosin. Too bad Dboys doesn't have one then you could just use the parts from that like I do with the Kar98.

oberst42, its half inch.
I added it to the guide btw

[cairo1]

so now dose the bolt handle wobble freely, or is there some device that keeps it relatively steady.

moreover, in regards to the safety lever, when locked, can the bolt be turned? the rifle be cocked?

additionally, when can we expect more Instructions.

I find this enthralling

[Sgt_Tom]

I am very sorry I haven't got around to making more instructions, I've been soo busy lately. The bolt doesn't wobble at all if you follow the directions. The bolt handle can't be turned when the safety is on but its still possible to cock the bolt back and fire so its a bit useless.

[Boshman]

I have just noticed a bit of flaw in your bolt conversion. When you cut off your bolt handle you have cut it flush with the front of the handle!

If you look at an original VSR10 bolt handle you will see there is about 3mm of the main body infront of the front face of the handle!


By not having this, the bolt will not actually close fully as the bolt handle will come into contact with the receiver face before the bolt is fully home so the nozzle will not fully engage the hop seal and it will lose air seal and power!

Fixable with a spacer I guess but better to cut it further forward of the handle. I actually cut mine 3.5mm infront of the handle so I have a bit of leeway and can file it back and correct it incase the cut is not 100% square.

[whiterook]

Could the difference here be that you are using a VSR 10 and his converstion is using a JG BAR 10

[Boshman]

Oct 6, 2010 13:37:33 GMT -5 whiterook said:

Could the difference here be that you are using a VSR 10 and his converstion is using a JG BAR 10

Nope! All of my conversions have also been done using the JG-Bar10. Besides it is pretty much an exact copy of the VSR-10!

[Sgt_Tom]

Boshman, the way I do my conversions it works. I'll show you how I make it work later.

[godo]

What is the length of the inner barrel on the finished product? Do you keep using the original size or can you go up a size?
Is it worth getting a long barrel and then maybe chopping it down?

[Sgt_Tom]

I just use the stock inner barrel both the shorter downgraded barrel and the regular one work. I bought an upgraded barrel for mine and it didn't need any shortening.

[blackwater]

gonna have to get a broken dboys just to try this out...been wanting to start a german impression after november anyway. good guide so far man!

[furrycow]

Is this considered a necropost? And if not, Can you tell me the next step .I just purchased a dboys Kar98k and already have a BAR-10amd I would like to do this conversion

[Sgt_Tom]

No its not a necropost. I currently do not have a rifle that I can use for this guide, once I get one, may be a while, I finish the guide. All the rifles I have are too far along to go to the next step.

[cairo1]

using your guid as a spring board, i have started on my K98. still havin some problems with the slanty trigger disengaging thingy, and am now thinking about how to mount the sights, but its going great. i also innovated a Mag Catch using laminated paper plasticard and E-Tape. i will get some pics of it after i get my stock from R-Guns

[Sgt_Tom]

Slanty trigger disengaging?
As far as mounting the sights you need to cut off the sight box, then glue it into place with epoxy. You can also reinforce it with a screw but it isn't necessary. For the Magazine catch why not just use the BAR-10 one? Its simple and works well.

[cairo1]

Slanty trigger disengaging thingy AKA the bolt coming out stopey thingy, that when depressed disengages the trigger. id look for the part # in my Manuel, but i used it as a base for mixing JB weld.

and that single piece is now my greatest obstacle >:3

planning on grinding the receiver tomorrow

[Sgt_Tom]

Are you talking about this?
hotspotairsoft.com/catalog/images/pss10_spgs_02.jpg
If so I could send you a spare I have.

[cairo1]

no, no. actualy i have sloved my problem, some pipe amd JB weld fixed my little problem.

should i wait to get my stock before i attack the rear sight, i think i might have too

[Sgt_Tom]

Yea definitely wait till you get your stock and fit it inside the stock. That way you can see if the rear sight is lined up right before attaching it.

[cairo1]

gunna go get an RC stock tommarow.

[Sgt_Tom]

(I posted the images as direct links as the image display wasn't working well ).

Here is a guide on how to fit the BAR-10 receiver inside a Dboys K98 stock. We'll start with the lower receiver.

img718.imageshack.us/img718/8400/dsc09657mz.jpg
So for the first step we will attempt to fit the receiver and trigger group in the Kar98 stock.

img256.imageshack.us/img256/2074/dsc09658k.jpg
For this project you’ll need safety glasses unless you want plastic and metal dust in your eyes which will without a doubt happen.

img853.imageshack.us/img853/8515/dsc09669w.jpg
As we can see the metal piece sticking out of the trigger box is stopping the group from fitting into the stock. We will have to cut away some of the plastic for it to fit.

imageshack.us/photo/my-images/18/dsc09673f.jpg/
I first mark the stock where I want to cut it.

imageshack.us/photo/my-images/718/dsc09808i.jpg/
Here is the finished product. I use a dremel with a thin sanding disk to do this. A hand rasp will also work though it takes longer.

imageshack.us/photo/my-images/560/dsc09811i.jpg/
The stock now fits in partly but not all the way.

imageshack.us/photo/my-images/521/dsc09812.jpg/
The lines are faint but you can see the markings where it needs to be sanded down. Finished product is below.
imageshack.us/photo/my-images/842/dsc09840g.jpg/
imageshack.us/photo/my-images/844/dsc09844z.jpg/

As we can see the receiver still does not fit inside the stock.
imageshack.us/photo/my-images/31/dsc09845g.jpg/

The piece we see in the picture is too wide to allow it to fit in.
imageshack.us/photo/my-images/191/dsc09846q.jpg/

We simply cut it thinner like we see in the picture below. I used a dremel with a thin sanding disk again for this.
imageshack.us/photo/my-images/196/dsc09849f.jpg/

Next step is to clear out the magwell area so magazines can be inserted and so the upper receiver section can fit.
imageshack.us/photo/my-images/196/dsc09849f.jpg/
There is a layer of plastic as we can see which needs to be cut out. A thin sanding disk is again used for this. The process is simple just cut of the layer with the dremel tool.
img88.imageshack.us/img88/5563/dsc09856y.jpg

And finished.
imageshack.us/photo/my-images/7/dsc09857h.jpg/

As we can see the upper receiver still doesn’t fit.
imageshack.us/photo/my-images/84/dsc09858f.jpg/
imageshack.us/photo/my-images/853/dsc09859d.jpg/
As we can see there is a piece of plastic in the way which needs to be removed.

Mark the area that needs to be cut with a marker/pencil first, like so.
imageshack.us/photo/my-images/545/dsc09862v.jpg/

Then cut away.
img685.imageshack.us/img685/3844/dsc09865q.jpg

Now it should fit in, partly that is.
imageshack.us/photo/my-images/840/dsc09866l.jpg/
As we can see the barrel is in the way of it fitting.

Line the handguard up to the receiver to see where it needs to be cut. Then draw a line to mark it. Make sure the holes that attach the piece that connects the the hop up isn’t going to get cut off.
imageshack.us/photo/my-images/811/dsc09867j.jpg/

It should look like this when finished.
img201.imageshack.us/img201/3001/dsc09868n.jpg

As we can see the receiver still doesn’t fit in.
img706.imageshack.us/img706/8003/dsc09869ej.jpg
You’ll notice the gap it needs to go inside is not wide enough.

Again we mark the lines where we want to cut and then go for it.
imageshack.us/photo/my-images/585/dsc09870t.jpg/
Do this part slowly as what you cut off is hard to get back. Its not a huge problem if it’s a little wider then it needs to be but it doesn’t look as professional when it is.

Done!
imageshack.us/photo/my-images/195/dsc09873q.jpg/

Finishing sanding can be done with a hand rasp, fine grain.
img407.imageshack.us/img407/569/dsc09902r.jpg

Now it should fit perfectly
img213.imageshack.us/img213/1102/dsc09871n.jpg

[2nd Bat]

Your magazine hole looks smaller then a VSR mag. If I remember you made your VSR magazines a bit shorter. How did that work out for you? Did they work okay? And how many rounds did they feed once cut down? If i remember you did so to allow them to fit in the pouches. How may of the Kar 98 d-Boys marriages did you end up finishing and selling? I think there are several folks obviously looking to do this product so if you could finish out this tutorial it would be awesome. So far it is super helpful.

[shiftysgarand]

I think if this is expanded a bit, it deserves a sticky.

[volkssturm]

Very helpful, but I have a problem. How do I separate the piece that holds the safety from the end of the bolt. I've taken two screws out of the end of the bolt. The two pieces don't seem to want to separate. I can't see anything holding them together.

Nevermind. There was a third screw holding things together. I just didn't turn the bolt far enough to see it.

[Sgt_Tom]

Jan 7, 2014 0:20:30 GMT -5 2nd Bat said:

Your magazine hole looks smaller then a VSR mag. If I remember you made your VSR magazines a bit shorter. How did that work out for you? Did they work okay? And how many rounds did they feed once cut down? If i remember you did so to allow them to fit in the pouches. How may of the Kar 98 d-Boys marriages did you end up finishing and selling? I think there are several folks obviously looking to do this product so if you could finish out this tutorial it would be awesome. So far it is super helpful.

If I ever do another Kar98 conversion I'll write up more on this guide. I ended up making about 7-8 of them. The finally got the process down with the last 3 I made. The previous ones didn't function all that well. I spent far to much time on them. I am the type of person that wants everything to be perfect, which isn't ideal when in the custom airsoft gun business.

The magazines I used were shot gun magazines that were identical to the VSR-10 mags except shorter.
www.airsoftoutletnw.com/utg-m50-shotgun-magazine-for-m87t-and-mb5s-airsoft-shotgun

They are cheap too.

If anyone has any questions I'd be glad to answer with pictures.