Wow, I like where this is headed! I'm also willing to help out as part of Team Khimara however I can. I do have some suggestions to consider going forward:
1. The Khimera is useless to nearly all of us unless it gets BATFE Tech Branch approval. I'd suggest that the collective knowledgebase here screen potential designs based on current policies for such uppers. Once a candidate is downselected, the solidworks design should be submitted to the Tech Branch for review. If they don't have any issues with it, then the first prototype could be made and submitted with high probability for approval. It would probably be smart to have an 07FFL/02SOT make and submit it just in case the prototype ends up as a machine gun.
It is my limited understanding that the NFA Technology Branch doesn't have a huge budget/unlimited funds. Somehow sending them a computer based design seems problematic. The Tech Branch isn't an engineering design shop. It is a Govt. entity. It would seem to me that whomever does this Khimara upper, an actual "upper" of the basic principal of operation to be used needs to be submitted. The Tech Branch would evaluate it and decide if what was submitted was or was not a firearm. As with the XMG, if the Tech Branch rules that the design is a firearm (and must be transferred via a 4473) then selling that firearm as a full auto conversion would be problematic. I think programing should be for final design, as it is expensive.
Try to eliminate the need for drilling a hole in the rear of the receiver from both a technical and BATFE standpoint. My opinion is that sales would probably be 25% greater or more without the required hole. But, if you absolutely have to drill a hole to get it approved, then so be it. Drill baby drill!
That to me seems very sound. I think I have a design that will pass muster with the Tech Branch that will not require the hole in the RR.
Keep as many standard AR-15 parts as possible. From a consumer's standpoint, I would like to be able to just buy a stripped Khimera upper and whatever else may be required that is non-standard to an AR-15 (likely the carrier, recoil system, etc.). This would allow me to buy and replace whatever barrel length/caliber I want, use whatever handguard I prefer, etc. I would be much more likely to buy multiple uppers for even one lower (think $$ sales). Plus, it would drive manufacturing costs down (i.e., margins up) for sales of complete upper halves.
While it might be easier for some buyers to deal with final assembly with their own parts, that puts more of the reputation of the product in the consumer's hands. It is my intention to sell complete upper package that I have tested for function. So when the consumer receives the product, I'll know it will function. My plan is basic direct impingement AR function, using a quality basic fore end. If then the consumer chooses to add/change parts, that is on him. But to send a stripped upper (other than the specialty parts) and have the consumer put junk out of spec parts in it, then post all over the internet that it won't run and the upper kit is junk is not how I would want my business to be.
Keep it light weight. Use aluminum alloy wherever possible and put it on a strict design diet.
Absolutely, the AR is based on being made from light weight aluminum "receivers". The basic shape of a AR A3 upper is what the fore end would connect to in my "upper" design. I think the biggest fault of the S.A.B.R.R.E. upper was how heavy it was. Right behind that is all the specialty parts that I don't think was needed. Why A.A. didn't use a standard fore end, I don't know. But that is not how I wish to build.
Keep it simple. While interchangable mag-wells is a nice concept, the standard AR mag-well is more than sufficient IMHO. If all goes well, then roll out another upper with an AK mag-well that will accept drums, but keep everything else standard AR (like the MM-47)...not AK.
You of course are entitled to your opinion, but to me one of the big advantages of the AR-15/M16 is that it is that it is modular. I think the MGI lower system with their interchangeable magwells are the ultimate in modularity. Time will tell how best to do that and costs, but that is my intention to start with.
I'd actually suggest targeting the design around the M11-A1 platform first. This would allow an easy design modification to the M11/9mm since they are exactly the same except for the added length at the rear of the receiver. Retrofitting the other way would likely be much more difficult. Including the M11-A1 would also increase sales. Hopefully this would also help with the eventual M-10 design since it is essentially a scaled up M11-A1.
While that sounds great, we are talking about a rifle caliber upper, to start with based on the AR. To me the M11-A1 is too small to get everything to fit. There is also just the shear numbers. It is my limited understanding that the lion share of transferable MAC style RRs are M11/9. Quite a ways behind that is M10 (both M10/9 and M10/45). There are what a couple thousand M11/M11-A1s? Not every owner is going to buy a rifle caliber conversion. Why does Richard make so few M11 (not M11/9) products? Because they don't sell. What percentage of current owners would buy a rifle conversion? One percent or even less? Especially to get a MAC style RR rifle conversion business off the ground, the initial product, I feel, should be a conversion for the vast majority of the possible buyers. I don't think the sales numbers would be there for the M11-A1. As time goes by, I would be willing to look at the M11. I don't currently own one. Eventually I'd like to, but that would be down the road.
Keep the price point reasonable. We Mac owners generally don't have as much spare cash as other MG owners.
The whole point of using as many AR-15/M16 parts as possible is the price, quality and availability reason. "Re inventing the wheel" i.e.making custom parts is expensive. I plan to use as many "off the shelf" quality parts as possible to keep costs down. I'd like to keep the actual "upper" cost down. Run a Beta C or two and change out the upper. Pistons are expensive and don't address barrel heat. Changing the "upper" with the hot barrel to an "upper" with a cool barrel does.
I think if you keep as much of the design standard AR parts based, this legitimately opens the door to an eventual belt fed upper design. The Valkyrie Armament belt feed system would likely be a good candidate and they seemed willing to partner with the SlideFire people, so might be interested in partnering with Team Khimera.
v/r,
Esox
Call George or write him an email. His contact info
http://www.beltfedar.com/belt_feed_conversions/ has the phone # on the bottom of the page and his email is on the link at the bottom. The last I knew George's belt fed design is still tied up with the Slidefire company for the next year or two, I can't remeber.
As I've posted previously, I have a design for a rifle caliber conversion upper that I think will "past muster" with the Tech Branch and won't be considered a firearm, without drilling a hole in the RR. I don't have the ability to build all of the prototype myself. I have a shop locally that can build part of it. I think I have the possibility of someone else that can build the second part so I can finish it. I'm basing the prototype on the AK mechanism because it is a sheet metal design. The MAC style RRs are also based on sheet metal. So I can do some of the fabrication myself.
In my mind I need a cheap prototype of my basic design. Once I get a ruling that what I want to do is not a firearm, then I'm willing to invest in the programing for CNC machined aluminum based on the AR. Eventually I'd like a conversion based on other firearm mechanisms, but that is down the road. I left home the end of February and just got home two weeks ago today. On June 24 my family and I are leaving Las Vegas and moving to Southern New Hampshire. I just don't have the time to chase down the prototype right now. Once we are settled, this is very high on my list. But I need to move first. I bought my RPB M10 as a lark as I already own a DIAS and Fleming HK sear. I bought my M11/9 specifically for this upper idea. I think the two models cover almost 95% of MAC style RR. I sincerely wish "Team Khimara" all the luck in the world. It is my understanding that my design differs from the Khimara concept. I don't really want to get into the details as I am hoping to patent the difference and turn this into a full time small shop business like Lage. A guy can hope.
Scott