Magpul bad lever is sloppy

[Crankbait]

I install bad levers on all my ARs. I just put one on an Aero M4E1 and it’s really loose. Any way to get it tighter? Do I need to replace the factory bolt release? This is my first Aero build. The rest of mine are BCMs and I’ve never had this issue. Thanks

 

[recreationalhandgrenade]

The bad lever is bad. I recommend throwing it away

 

[Bunsen]

I install bad levers on all my ARs. I just put one on an Aero M4E1 and it’s really loose. Any way to get it tighter? Do I need to replace the factory bolt release? This is my first Aero build. The rest of mine are BCMs and I’ve never had this issue. Thanks

The Magpul BAD lever is designed to fit on the standard ping-pong style bolt release. If it's loose and a standard bolt release paddle either it, the Magpul BAD may be out of spec. Also both could be at opposite ends of the spec, paddle undersized while the BAD is a little big. The least inexpensive fix would be trying a new bolt release, but those can be a PITA to swap sometimes.

I run BAD levers on nearly all my AR's and although I started with the Magpul I upgraded to the Phase 5 Tactical BAD aka extended bolt release which actually replaces the ping-pong bolt release. If you're going to swap the part maybe consider one of these:

Phase 5 // Extended Bolt Release V3 (EBRv3)

Phase 5 // Extended Bolt Release V3 (EBRv3)

phase5wsi.com

 

[11B CIB]

Before swapping bolt catches out, take the lever off and try to shim it. Maybe put a small piece of electrical tape (or something more firm?) around the bolt catch itself and reinstall the bad lever. That could give you some idea of what the issue is

 

[Timfoilhat]

What's loose? Is the lever installed tight but it wobbles? That's probably the small amount of play between the pin and the bolt catch. Something a little under size or a cut out slightly oversize. The longer bad lever just makes it really obvious when attached. You know this is the case if the loose wobble stops when an empty magazine is inserted.

 

[DrScaryGuy]

vaseline the release/catch and apply a little JB weld to mold the lever around it?
I did that with a 2-piece 1911 mainspring housing with optional mag funnel that had some wobble.

 

[Crankbait]

What's loose? Is the lever installed tight but it wobbles? That's probably the small amount of play between the pin and the bolt catch. Something a little under size or a cut out slightly oversize. The longer bad lever just makes it really obvious when attached. You know this is the case if the loose wobble stops when an empty magazine is inserted.

The lever is installed tight on the factory Aero bolt catch.

I took my caliper and measured the bolt catch on my BCM and it’s .137”. On the Aero is .129”. I swapped the bad levers around and same problem. So it’s the factory bolt catch on the Aero that’s the problem. I measured my other Aero lower and it’s .128”.

Looks like I’ll be ordering a couple bolt catches.

 

[Cole_McD]

I've got bad levers on all my lowers and I have one that's a bit sloppier than the others (funny enough it's also an aero lpk 🤔).

Interesting info! I may try shimming my sloppy one.

 

[CarolinaColtCollector]

I have moved my bad lever around on lowers and had this issue, I shim it with some (slightly) crushable polymer or get the M4 aero lowers so I can just unscrew the release and put one that works in its place.

 

[Crankbait]

I have moved my bad lever around on lowers and had this issue, I shim it with some (slightly) crushable polymer or get the M4 aero lowers so I can just unscrew the release and put one that works in its place.

Both of these Aero lowers are the M4. Which ones did you replace it with?

 

[CarolinaColtCollector]

Both of these Aero lowers are the M4. Which ones did you replace it with?

I had some laying around in my parts bin from all the stuff I’ve swapped out, I couldn’t tell you who they were from specifically. The M4 is just easier since you can unscrew the retaining pin vs punching one out and back in.