I just remembered AirsoftGI posted this on Facebook a few weeks ago. I didn't see any threads about it so I want to share this with you guys DangerWerx is creating a shotgun rail for UTG/DE trishotties.
Looks like an AR rail that is mounted to a hand guard; not only that but it looks cheap as hell.
The rail is actually CNC'd from 6061 Aluminum Billet, not a modified AR-15 rail. I can't afford Alum casting yet, probably never, so CNC will the best bet for one-time limited run of 50 units. My production rails will be injection molded of glass reinforced polymer.
The rail costs half of what the shotgun would... just drill holes into a regular rail and tada!
The price of the limited edition rails are high, because they are cnc'd in the US from a single block. My upcoming polymer rails will only be a 1/4 the cost of the shotgun, about 15 dollars. It is a much better ratio, but I understand I cannot compete with a Chinese-level margin. I'd like to keep my local machinists and mold shops employed.
The reason I avoided re-manufacturing rails is actually because of the inherent problems of "just drill holes into a regular rail and tada!". I have probably wrecked 2 foregrip retention plates after attempting just that. You can see a comparison photo of my rail and a standard G36 rail here.
I had to increase machining time by including 2 support struts which bridges the gap from the rail and the provides pumping support.
I came to this conclusion, because the screws used to mount a regular straight rail to the fore grip leaves about a .35 inch play from the screws cap to the actual retention plate. I don't have my notes with me, so I might be off.
Once users begin the pump, the lack of immediate support causes the screw to buckle laterally and break the foregrip mounting holes and eventually strip out the retention plate. This can be solved with a liberal application of epoxy into the counter screw holes, providing a void-filling support, but that would negate any possible disassembly of the shotgun.
The addition of the struts allows the lateral force of pumping to be redirected and braced into the thick walls of the foregrip and the screws supply a clamping force into the retention plate.
I also include longer screws that tap deeper into the plate. The factory screws get about 2.5 thread revolutions into the plate, barely enough to meet common manufacturing standards. My included screws are long enough to cover the gap of the rail, foregrip and then provide a solid 6 thread revolutions into the plate, allowing a strong and forgiving mounting, greatly diminishing the chances of a user stripping the rail from the plate.
Like you guys, I thought this would be an easy problem to approach, but in doing my due diligence, the easy way out would be very irresponsible of me, risking player guns for some quick cash. It might cost more, but it is because I wanted to do it right.