Shortening a gas tube
This is the easiest way I have found to shorten a gas tube and still have it look and function good. I start by cutting the gas tube into three sections as shown. I then use a Dremel to dimple each spot weld on the hand guard retainer. Once this is done I drill a .125" hole through each spot weld.
Once the holes are drilled I punch out the old section of the gas tube. Next I cut the two ends of the tube to the proper length making sure that they are square with each other.
I now insert the two pieces of the tube into the hand guard retainer and line them up so that the seam is centered in as many of the holes as possible. I insert a piece of .625" rod through the tube to keep it straight.
Using brazing rod or high temp silver solder fill in each of the holes. I will also braze or solder the ends where the tube sections enter the had guard retainer for added strength.
If you plan to do a parkerized finish you will want to use a TIG or MIG welder. For a sprayed on finish the brazing rod or silver solder will work fine.
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