The document proposes customizing existing AK-47 rifles used by the Indian armed forces by replacing certain parts to improve ergonomics and functionality. Key proposed upgrades include adding continuous Picatinny rails, shifting the rear sight back for improved accuracy, adding a five-position extendable and folding stock, and including a windage adjustment on the rear sight. The upgrades are designed to enhance an operator's capabilities without compromising the rifle's reliability, and could also potentially be applied to the INSAS rifle. A cost analysis found the maximum material cost per customized rifle would be about 300 Indian rupees. The customization concept aims to meet military requirements at a low cost compared to procuring new rifle systems.

1. THE CUSTOMIZATION
CONCEPT
CONTENTS:-
1. THE PROBLEM
2. VIEWS FROM INDIAN ARMED FORCES
3. THE SOLUTION
4. ADVANTAGEOUS FEATURES
5. MATERIAL COST ANALYSIS REPORT
-EKANSH CHATURVEDI

2. THE PROBLEM
The major problem faced by current operators of AK-47s/ AK-Ms is the lack of modern ergonomic
features, for instance a continuous Picattiny rail on top , bottom and desirably if present on both sides
of hand guard too; collapsible and foldable butt stock and an easy windage adjustment facility on the
rear sight mount.
This can be visualized in the picture below:-
No Picattiny rails
Uncomfortable
stock with no
extendibility

3. VIEWS FROM INDIAN ARMED FORCES
1. According to a latest report on defense items procurements by armed forces it has been found that
Indian armed forces and particularly Army, are struggling with their currently issued INSAS rifle while
Kalashnikovs still remain the soldiers’ most favorable choice due to renowned ruggedness and
reliability, specially when deployed in Kashmir and Naxalite prone areas.
2. Also, started had been some talks over procurement of a new common issue rifle for Indian army
replacing the defamed INSAS. Some renowned vendors like Barreta, Colt, IWI, and Ceska participated
with their products, which were unfortunately the procurement deals were trashed to cold shoe.
Although, according to defense ministry’s statement , the talks would again be initiated in 2017.
The customization concept has been brought up by keeping the aforementioned problems in mind.
THE SOLUTION
This concept proposes to customize all the AKs in the Indian arsenal to compete with their modern
counterparts and to enhance the capability of an operator and if given a green hand, the similar
designs can be applied on INSAS system, if desirable to the military.
This concept mainly focuses on replacing certain parts of the rifle with improved versions which
include all the previously lacking ergonomics. Addition to it, it is to be mentioned that the
components have been designed such that there would be no tempering with the mechanical
working components, i.e. the lower receiver and the barrel assembly. Hence the lower receiver
would be left intact thus ensuring the same reliability, durability characteristics but with enhanced
performance characteristics.

4. The components to be replaced are mentioned as follows:-
1. Top cover
2. Upper and lower hand guards
3. Rear sight
4. Butt stock
Their replacement alternatives are mentioned as follows:- (fig 1.1)
1. Top cover and upper hand guard as one single piece hinged with a foldable and extendable butt
stock; having a continuous NATO STD Picattiny rail on top and screw holes on sides for mounting
side rails.
2. A separate lower hand guard with a NATO STD Picattiny rail at the bottom.
3. Rear sight is shifted from middle portion to back along with a provision of windage adjustment facility.
Fig 1.1

5. ADVANTAGEOUS FEATURES
1. CONTINOUS NATO STD PICATINNY RAILS:- The rails facilitate the operator to comfortably use
the non-conventional sights such as Red- dot sight holographic sight, night vision devices, laser
designators, front grip handle etc.(fig 1.1 and 1.2)
2. SHIFTED REAR SIGHT:- This increases the distance between the front and rear iron sights thus
improving the conventional accuracy.(fig 1.3)
3. 5 POSITION EXTENDABLE & FOLDING STOCK:- The stock is made of POM acetal polymer/
Delrin with five extendable positions and is also foldable to right side. It is designed such that it would
not interfere with the bolt’s reciprocation during fire. Hence it enables the weapon to be fired from
folded stock position.(fig 1.3)
Fig 1.2 Screw holes for mounting side rails
Bottom lug to befit in lower receiver

6. REAR SIGHT POST
5 POSITION EXTENDIBILITY
Fig 1.3

7. Fig 1.4
4. WINDAGE ADJUSTMENT FACILITY ON REAR SIGHT:- Older versions of AKs lack windage
adjustment facility which, here, can be easily done with just rotating a screw on the housing. The range
adjustment mechanism remains the same.(fig 1.4)
5. DISASSEMBLY PROCEDURE:- Unlike the traditional style disassembly process, this consists of
disassembling the two push- pins and the whole rifle opens up along with the gas tube. There is
no separate pin for holding gas tube in place. The pin that keeps the top cover attached with
trunnion also holds the gas tube in place. Also, the upper and lower hand guards are not kept
intact by any retaining plate unlike that in the older version. The upper hand guard is pivoted to the
lower one at the front. Such design provides extra ruggedness to the rifle’s structure integrated
with simplified disassembly.(fig 1.5 and fig 1.6)
Windage
adjustment
screw

8. STEP 1.
The two push pins are pushed out. It
is to be noted that the rear push pin
gets inserted into a hole in top cover
aligned with a counterpart in the lower
receiver.
Disassembling the push pins
Hinge at the front end of upper and
lower hand guards
Fig 1.5
Fig 1.6
STEP2.
Pivot up the top cover
about the hinged end and
pull the fixing lug at the
end of lower hand guard
out of the lower receiver’s
front end.

9. MATERIAL COST REPORT
MATERIAL USED WEIGHT OF
MATERIAL USED PER
RIFLE
MAX MATERIAL
PRICE *
MAX PRICE OF MATERIAL
USED**
ALUMINUM
7075 ALLOY
590 gms 4000$/ ton INR 165
POM
ACETAL
COPOLYMER
310 gms 6000$/ton INR135
** 1$= INR 70 approx
Max total material cost per rifle= INR 300/-
* source- alibaba.com

10. CONCLUSION
The customization concept has been designed keeping the army’s requirements, benefits,
expenditure, as well as political and financial aspects in mind.
Hence, it could be beneficial to customize, or say, modernize the equipment of soldier’s favor to meet
the lacking features instead spending unnecessary time and capital in procurement of new ones and it
becomes more important when the military suffers with INSAS.