Chopped my class 3. FINISHED! (Pic heavy)

[Zloyvolk]

So, after a couple of years of frustration because of the insane height of the PS90 sites, I decided to lop off some metal and see what I could come up with. Let me preface all of this with, this is technically my wife's gun. Sure, I do everything with it include shooting it but I have to get permission for it all. She doesn't know I did this yet, just that I wanted to work on it. Her biggest complaint with this gun was not so much the optic height but the weight of it. So, using the two birds, one stone theory, I went to work.

Everybody should know first off, I have no fancy tools or even machine skills for that matter. Everything was done with a Dremel, hacksaw, and files.

I measured the height of the Eotech (app where the cross hair would be) to the barrel just to get an official start.[/img][img]


I weighed the receiver (with barrel since I'm to lazy to disassemble any of it further).[/img][/img]

I spent a good amount of time contemplating about how I should go about f'ing this up. Once I decided, I made some ruff markings and went to town. Incidentally, I couldn't get the rail detached because of a stripped allen screw so I left it. It was all coming off anyways.
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I started across the back side with the dremel. It went pretty quick. Thank god it's aluminum.[/img][/img]

Once I got through as far as I could, I started down the sides.[/img][img]

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I was happily surprised by how quickly this was accomplished: maybe 10 minutes.[/img][img]

Once I finished getting everything I could reach with the dremel, I had two spots which were still holding it. The first part was the front left hand side. The metal was a little thicker on this side. Using my handy dandy hacksaw, I made short work of it.[/img][img]

The second spot was the spot right in front of where I originally started. again, little thick for the dremel. I had to remove the hacksaw blade from the holder and go at this old school style. 10 minutes or so, I was thru.[/img][img]

Now was the time to discover if I would end up sleeping on the couch or maintain my healthy marriage.

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Oh, yeah!!! [/img]

Everything up to this point went pretty quick. Less than an hour I would say. Now the time consuming part would begin.

I started filing it in the back.[img][/img]

Using a flat file and a round file for the curve, it took a half hour or so. I polished the grooves (which were very light if at all) out with the dremel.
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Minus future touch up work, this was what I ended up with. [img][/img]

Filing this huge hump down took time. It was solely for cosmetic reasons.
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Minus future touch up, this is what I ended up with.
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This is officially where the beginning of hating myself began. I had to file down the little ridges and then the huge mass on the front. I used the dremel a little but worried about gouging to deep, so mostly hand file work.
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FML!

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Finally, the ruff finish.
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I like it! Little touch up work still to go.
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I ordered a Magpul Moe rail (2.5") which I will attach after I drill and tap. I wanted to make sure that my front end was as flat as possible. After brushing the aluminum with the dremel, I carefully ran the flat file across so I could see the contact marks. Eventually, the part of the receiver that was to low showed itself and I knew what had to be done further.
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I worked everything over with the hand file till it looked perfect. This is my final product before the rail gets here. [img][img]

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The height of the sight will have been reduced by 1.5" and the weight reduced by about 2/3 of a pound (which includes the rail I had on there). The whole project took maybe 5 hours. Mostly slow going with the file work. I'll post more when the rail comes in, the Eotech is mounted, and the whole thing is re-Duracoated. My wife was in the Air Force, so I'm going to do something using that theme. Maybe a barcalounger . We'll have to just see.

Hope this motivates some of you to try it. I think it was well worth the time and effort. [/img]

[CountryBoy]

I would have though the site was put at that level due to the stock design but im a n00b when it comes to P90s. interested to see the final results though

[FullAssault]

wow that's low!! I'm interested in see how this turns out! Btw what are you doing with the left over top?

[stang1]

OH YEAH....

[ninthinning]

This is good work. I have been thinking of this sort of thing for awhile now. Looking forward to your progress.
9th

[Vanman2004b]

Looks good so far. I too want a lower optic on my standard, but am not willing to give up the BUIS. When you are finished I may reconsider.

[SONYtec]

WOW, 5 hours and hand tools. Looks good!!!

[Thermallator]

Nice work! Keep us updated as to the progress.

-TH

[124C41]

You are very artistic, I bet it turns out well.

[Dafoosa]

looks like now that you have an audience you better get busy on that rail.....By the way I have been looking into this myself and it looks great