PPSh-41 AEG (The improvement of Hexagon replica)

There were several things in this replica that needed refinement:

- the front wall of the barrel sleeve and barrel sleeve itself
- front sight guard
- rear sight
- the colour of the wooden butt

Barrel sleeve

The shape of the barrel sleeve and the need for improvement is visible from the first look
 Flat portions look badly and have to be rounded to resemble real example

I have used as an anvil two short steel rods (10 mm O.D.) welded together perpendicularly to
get a “T” shape of width just to allow it to enter holes in barrel sleeve.

On the other hand the bottom of barrel sleeve is cut along whole length whereas it should be
welded beneath the portion working as flash hinder and recoil suppressor. The front wall of
barrel sleeve is welded not accurately and the excess of metal was not filed off.
Using regular file and water-proof sand-paper I have smoothed front wall

Than I filled not required gaps and the surface with regular epoxide putty, usually used for car
body repairing.

The results, even the surface was smooth and good looking were not satisfactory as, even
sanded with 1000 grind paper, the surface had different shine than original metal.

Therefore I have decided to use “liquid steel” epoxy instead. ProWeld® Quick were very
satisfactory. After hardening, filing and wet sanding both surfaces were comparable.
Front sight guard

Before

This part was made of very thin sheet of steel (0.5 mm) and snapped into groves made in the
front sight base. The overall shape as well as the shape of top and side holes was not acurate.

I took a piece of 1,5 mm thick steel sheet and made a new part using as a template drawings
from Russian War-Time Service Manual.

As this instruction said, that this part could be either spot welded or fixed with rivets I have
decided to use ready short steel blackened 3 mm O.D. x 3 mm h rivets.
 After

Rear sight

In replica the base is spot-welded to the receiver cover/barrel sleeve. As the front sight guard
was riveted I have decided to use this way of fixing also in this case.

The colour of the wooden butt

At the time of purchase the only one variant of butt was offered by Hexagon – with unnatural
very light colour

Complete removal of the paint and lacquer and subsequent re-dying with varnishes used by
professional gunsmith workshops helped to get proper appearance.
FINAL LOOK
That’s all Folks

©Walther38
2010