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As per the title, what options do I have to mount a flashlight to a standard Bushmaster ACR fore-end? I don't need anything too fancy or expensive, just a solid, rugged flashlight mount (ideally looking to mount a light with a pressure switch).
If you are hell bent on a pressure switch, a Surefire SR-07 on the top rail might be the ticket.
If you have the option to run a button cap on a surefire, it will be the best option as it saves weight, keeps bulk and snag points to a minimum, and is cost effective. It gives you either momentary with partial press or constant on with a full click.
Also to note I have switched my charging handle to angle downward now, which acts as a thumb rest now and also allows clearance for my PEQ-15 (not pictured) to sit in front of my Elcan.
I dont believe they make the MOE rail in metal that fits the MOE handguard. I have a MOE rail section for my ACR rail that is used for my Atlas Bipod with no issue so im pretty sure alight will be fine.
Ill check my parts bin, I probbaly have a spare section I can give you. Ill look when I get home.
I use a left side MOE scout mount for my x300 when I want a light, although I did have to file a cross slot for the locking bar on the x300 due to where I mounted it. It puts the light in the perfect spot and works as a thumb rest.
Why worry about a polymer rail when the handguard you're mounting it to is polymer and it's only for a light.
Handguard is a much larger unit. My concern with a polymer mount is wondering if recoil (albeit light on a 5.56 rifle) would cause gradual wear between the metal flashlight mount and polymer rail. I've seen the MOE rails mentioned a bit, but have never used them personally. In my experience, just because something is used by many doesn't mean it's necessarily a great option. However it seems like people trust them! Thanks for the info fellas!
Unless your light mount is loose I don't think there will be any perceivable wear. I also have one on my 3 Gun ar that has been on there for a couple of years, I have smashed it against different barricades without issue.