Issues with Upper Receiver / Charging Handle

[tal3nt]

On one of my well used and abused ARs, the step-notch on the upper receiver where the CH latch catches on to is completed rounded out.

Every other shot or so, the charging handle will pop me on my nose before the bolt comes forward again to bring it back into battery. It doesn't pop out with the full speed of the cycling bolt; just fast enough to be annoying.

Also, on the last round when the bolt locks back to the rear, the CH pops out, hits me in the nose, and remains rearward..

Do I have any other options besides replacing my upper receiver?

Do your upper notches look as bad? Has anyone had this same issue?

Thanks in advance

[BrianRodela]

Take it to someone who is very comfortable with a rotary tool and a fine squared off bit to reface the edge. Your finish will no longer be there but it will function. Also might not be a bad idea to replace the latch on the charging handle to match. Just curious, how long have you had the upper?

[tal3nt]

17 months and ~4,000 rounds..

When I do need to use the CH, I'll typically side charge with my left hand ( I'm right handed) while the rifle is still shouldered.

I use a standard forged CH for this particular rifle.

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What if I drilled out that notch all the way through?

[BrianRodela]

That's actually the preffered method as it keeps control of the rifle while shouldered and on target. I am surprised it went so fast to be honest but it can be repaired without replacement of the upper receiver. Shouldn't be a problem.

[tal3nt]

I think the standard charging handle may have expedited the wearing process..

I've noticed that on my other rifle, which has a gunfighter on it, the latch opens up and clears the notch completely before being able to actually charge the weapon. Hardly any wear on that receiver..

I wanted to keep this one as m4gery as possible though

[triggs75]

Have you tried another charging handle to see if it will still pop out

[tal3nt]

Threw in a new forged milspec CH i had lying around.

Havent shot it since. Will report back, but i imagine it would fix the problem temporarily until the new latch eventually wears the edge even more..

[70 blazer]

if you had a small mill or a friend with one you could reface it clean. local gun shop can do it too.

[gemini1]

What brand upper is it? I close to the same round counts on mine, but the wear on where my latch sits is nowhere close to yours. I dont charge it while shouldered though, so I dont know if that counts. My CH is just the regular type where the claw opens up fully when pulling the CH.

[el tardo]

take it to a welder and have him tig up a small roll there for about $20.00.

easy fix, dont grind anything away as it will get worse.

[tal3nt]

What brand upper is it? I close to the same round counts on mine, but the wear on where my latch sits is nowhere close to yours. I dont charge it while shouldered though, so I dont know if that counts. My CH is just the regular type where the claw opens up fully when pulling the CH.

Aero Precision. I have another AR with a higher round count that doesn't look half as bad..

I'm thinking I'll just swap to a brand new upper receiver and use a gunfighter CH.. Luckily I have access to everything I need to rebarrel.. I think I saw stripped uppers at PSA for $40