Illustrative Step-by-step

With this tutorial, go through each installation step with photos and a description of each step. To print out a full step by step detail of instructions, please click here!

Installation Instructions Overview of OPS-416 Gas Piston System

WARNING: The OPS-416 is a patent-pending product of Osprey Defense LLC, Osprey Defense LLC retains all patentpending,trademark and other rights including exclusive right of use, manufacture and sale.

The contents of this package shall be installed by qualified personnel only. This product should only be installed in MIL-SPEC weapons.

NOTE: Due care should be used in removing parts not used in conversion. They can be used as support inventory for other weapons or to restore your weapon to its original configuration.

Step 1. Put on safety glasses.
Step 2. CLEAR WEAPON: Remove magazine if one is present. Visually inspect the chamber to be
ensured that no ammunition remains in the weapon.
Step 3. Remove top and bottom hand-guard.
Step 4. Push both pivot pin and takedown pin left-to-right until stopped by detent. Separate upper from lower receiver.
Step 5. Remove the bolt carrier and charging handle from the upper receiver.
Step 6. Remove gas tube roll pin (It will not be used in conversion).
Step 7. Remove gas tube using gas tube removal tool (Fig. 1) (It will not be used in conversion).

Step 8. Install the piston chamber item #2. into the gas tube hole in the front sight tower until the role
pin hole aligns with hole in piston chamber.
Step 9. Hold weapon securely in pin removal/installation block and install the groove pin item #9 which will secure piston chamber item #2 to front sight tower (Fig. 2)

Step 10. Install bushing item #8 into upper receiver. Use Op Rod assembly to align and install bushing tap with a light brass hammer into upper receiver until it bottoms out (Fig. 3)

Step 11. Insert piston item # 5 into piston chamber (Fig. 4).
Step 12. Insert Op Rod item #1 through gas tube path (in receiver) rotate Op Rod (flat side down) for
appropriate clearance during installation. Then rotate Op Rod to flat side up for proper
alignment and engage it into piston and lock in place with retaining clip item #7 trough left side
and clip upward. (Fig. 4) Visually examine to make sure op rod is not rubbing on barrel nut. If so, call us at toll free 877-271-5616 (Tech Support) for further options.

Step 13. Remove bolt from bolt carrier. Remove and discard 3 gas rings (they will not be used in the
conversion).
Step 14. Reassemble Bolt (without gas rings) into carrier. Lubricate with Break free ™or other high quality lubricant.

Step 15. Lubricate and reinstall the charging handle and the bolt carrier assembly into the upper receiver.
Step 16. Reassemble upper and lower receivers. With the rifle closed, and the bolt carrier in battery, the piston assembly should have approximately 1/16 of an inch of forward to back free travel.
Step 17. Charge the rifle several times and check for normal function. Bolt carrier movements should be without abnormal resistance.
Step 18. Reinstall top and bottom hand-guards included with kit. Check bolt carrier operation.

Caution: Always practice safe firearm handling procedures. Improper handling or misuse of firearms may result in property damage, bodily injury or death!