We managed to visit the factory that produces sniper rifles and hunting rifles. We could not even imagine how difficult it all is.… But first things first.
The project itself for the construction of a plant for the production of rifles appeared most recently in 2008, and the first product was released only two years ago in March 2011. The plant was built almost from scratch, initially in its place were the premises in a monstrous state. May 15, 2010 started to overhaul. Flagship production — ORSIS sniper rifle — this is an abbreviated name for a phrase «weapon systems». But we will return to the history of the plant, and now let’s go inside.
My path passes through the workshop, in which the trunks are treated. The workpiece in which the hole will be drilled and cutting will be performed is called «form». Forms are delivered to the factory from the USA.
On such machines are processed parts for rifles. Here, in the blanks, they first drill a hole, the width of which depends on the caliber of the future rifle. By the way, some machines were designed in the design office of the plant with the assistance of consultants from Switzerland and Germany.
In general, the plant has more than 30 machines for various purposes with numerical program control (CNC). They are very different, there are simpler, for simple operations, and there are those that do really unique things, according to the technologies, which I heard about for the first time.
The trunks are made of special stainless steel weapons.
Pay attention to the coin. It stands edge on the moving part of the machine, which cuts the barrel from the inside. The smoothness and accuracy of the course in this operation is so high that it does not allow the coin to fall. At the end of the post you can see the video of this process.
The same machine. Here you can see how a rod goes off in the barrel form, making rifling — 4-6 spiral stripes, they help stabilize the trajectory of the bullet. The cutting is done with a special metal hook, which is also manufactured at the factory.
The tool enters the stationary workpiece and leaves a single micron depth mark on the cutter. To facilitate cutting into the barrel pours oil. The process of cutting the barrel lasts 3-5 hours. For one rifling, the tool should come in 60-80 times. After that, the barrel is manually polished with lead-tin lapping and cleaned of oil.
After these operations, the trunk enters the laboratory.
Here, experts probe the bore of a bore-scope (a relative of the endoscope) for defects — scratches, shells or cracks. The barrel is checked several times: after drilling the hole, cutting and polishing.
Go ahead to the second shop. Another little discovery — on the machine does not rotate the drill and the detail! The drill slowly crashes into the stainless steel.
What kind of wood we will find out a little later.
Pig, which will soon become the main part of the bolt mechanism.
The cnc machine processes the detail of the slide mechanism, which is immediately cooled with water.
Further, this item is subject to quality control. With the help of this device (on the left) the characteristics which the part should correspond to are determined.
The general plan of the second workshop.
Further our way lies through the shop where they make a bed. It is with this same jigsaw that a piece is cut out, from which an almost finished product will be cut out on the machine.
For each model make their own box. It provides structural rigidity. For tactical rifles use a bed of aluminum, for sports — from special weapon laminate. In addition, the plant to order makes a box of valuable wood, for example of walnut.
The machine also works on software control.
One blank of this part can cost several tens of thousands of rubles. If you carefully look at one of these bars, you can see 4 layers of plywood or as it is called differently. — wood laminate.
After processing on a milling machine, the craftsmen manually grind it, apply brand notches with a laser and impregnate it several times with oil. In one shift, the master makes 2-3 beds.
In the workpiece is a notch for the trunk, after which it is once again covered with oil and only then with varnish.
Let’s go further.
Here you can see how the blanks are ground.
Next we are waiting for painting shop.
And in the next room I was waiting for a small opening.
Here, using high-precision equipment (the cost of which amounts to tens of thousands of euros), parts for the bolt group (triggers, fuses, triggers) are cut out of metal, which could not be done with the help of other machines.
Parts are cut using electrical erosion technology. That such a thread, it can be from molybdenum or brass.
Everything happens like this: the thread from the coil is threaded through a small hole in a metal sheet or a pig, fixed from the bottom so that it can be wound onto another coil. Then this sheet is immersed in a bath of water, into which high voltage and current flows.
The thread is quickly wound on the second spool and the machine thus cuts out parts that are highly accurate to microns. This process can take 3-4 hours. Such a modernized jigsaw.
Here, too, CNC, a person only sets the program and monitors the accuracy of the operation.
Here from this disc is cut too much, so that you can insert another part.
And I was surprised that the thread can be cut at an angle. From the middle of this cylinder, a part is cut, which is round on one side and an asterisk in the other.
Details of the trigger mechanism.
Here you can see that several sheets were welded together to cut the maximum number of parts.
We are leaving this shop and are heading the assembly area; this is the last stage before the rifle enters the shooting range.
In these boxes are ready-made rifles.
The specialist collects together the details of the bolt group, attaches them to the trunk, followed by a glass bedding process. Special mastic is put on the bed for the rifle, metal parts are put into it and left to dry for a day. Then the parts are taken out again and given away for painting, and on the bed their exact impression remains, which allows the wood to be adjusted to the metal. This provides greater precision weapons.
After painting the parts are put together again. Specialists of the technical control department inspect the finished product and give a conclusion that the rifle is ready to fire.
At the factory there are very young workers.
Every day the plant produces up to 10 rifles per day.
In addition to rifles, the factory collects Austrian Glock pistols of various calibers.
And this is a refrigerator, but in it you will not find vegetables, fruits, beer, yesterday’s dinner and other snacks. It is also used when assembling a rifle. How, you ask?
The fact is that when assembling some parts, it is necessary to fasten some details to the bed as tightly as possible. If this is done at room temperature, the screws will crash too much into the product and may spoil it, so these parts are placed in the refrigerator for a while so that it squeezes a bit (I hope everyone remembers physics) and it could be screwed as tightly as necessary, without risk spoil the bed.
We leave the assembly shop and head to the shooting gallery. This is the final stage of checking the rifle for quality and accuracy. All weapons pass through the sighting.
You need to get a vooooon to that little point. See something? I do not) the length of the shooting gallery — 100 meters.
Testing the accuracy of weapons conducted by the master of international class shooting. The room here is small, about 2 meters by 2. We put on the headphones so as not to deaf.
High-class shooters have repeatedly won shooting competitions with this rifle.
By the way, Stephen Sigal is a big fan of hunting and weapons and ordered an exclusive rifle at the Orsis plant.
photo from the site of the plant
At the factory there is a salon of weapons, where you can look after yourself with a rifle, buy spare parts for it.
And a small video where you can see firsthand how all this is done:
We would like to thank Ekaterina Nuriakhmetova, the head of the plant’s press service, for the opportunity to see how all this is done.