Savage 64 charging handle

I made one using a 5/16" X 3" grade 5 bolt. I just chucked it in the drill press and used a couple of different files to shape it using the dimensions from the original. It took less than an hour.

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I'll show you how I made mine. I bought a couple of good Nicholson files from Princess auto. A single cut bastard that is 1/8" thick and 1" wide, a double cut bastard 1" wide. These were about $7 eaqch. I used a 5/16" by 3.5" grade 5 bolt and cut off the threaded part with a hack-saw. I measured 1" down from the top of the head of the bolt and marked that spot. I chucked the bolt in the drill press and lifted the table so the bolt extended through the table and the mark is flush with the table surface.

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Lay the 1/8" thick file on the table, start the drill press on a low to medium speed and while the bolt is turning hold light pressure against the bolt with the file slowly moving back and forth to prevent 1 spot on the file from overheating. This will cut the groove, the final dimension for the diamater of the bolt in the groove area is .190". With a sharp file this will take about 10 minutes. Stop and measure often.

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Then make sure the bolt has enough length so you can remove material above the groove to a length of .575". Use the double cut file to start to remove metal quickly but when the diameter get to about .260" switch to the single cut file for a smoother finish. The final dimension here will be .248".

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The bolt will look like this at this point.

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Cut off the remaining bolt above the machined surface making sure you have at least a lenght of .570" above thge groove.
With a grinder remove the six corners on the hex head of the bolt to make a roughly round head. Then chuck it back in the drill press on the .248" diameter.
Use a file held perpendicular to the table to gradually remove material from the head until it is round. I used a scrap piece of 1" square tubing to assure the file was straight at 90 degrees to the table.

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To flatten and smooth both ends I just laid a peice of sandpaer on the drill press table and lowered the ends down to remove material until smooth. The final finsh was done with 600 grit sandpaper.

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