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Are they legal? How do I buy one?
For the most part yes, however some states do not allow certain NFA items. Federally you must meet the following requirements: Be at least 21 years of age, be a U.S. citizen, have no felony convictions or domestic violence convictions, have no dishonorable discharge, not deemed mentally unstable by a competent authority. Basically the same rules for owning a handgun. The NFA rules/laws are posted through the BATF website.
At this time, the following states allow private ownership of silencers: AL, AR, AK, AZ, CO, CT, FL, GA, ID, IN, KS, KY, LA, ME, MD, MO, MS, MT, NE, NV, NH, NM, NC, OH, OK, OR, PA, SC, SD, TN, TX, UT, VA, WA, WV, WI, and WY. Of the sixteen states which do not allow civilian ownership, CA, IA, MA, and MI allow class 3 dealers and class two manufacturers to possess silencers.
Baffle strikes, what are they and what causes them?
As the round leaves the barrel is passes through a series of "chambers" called baffles. When a round is not properly stabilized it can "wobble" off center and can touch the interior of the suppressor.
Another issue which can cause a baffle strike is an improperly mounted suppressor. Before mounting you must first ensure that the threads on the barrel are properly lined up with the bore axis. Although someone may be good enough to use a "die" to cut the threads by hand the only "sure way" is to have a competent machinist/gunsmith cut the threads on a lathe. Next, if it is thread-on mounted then proper procedures must be followed to ensure a tight/correct fit.
How about traveling with a suppressor across states lines?
Approved 5320.20s are required for interstate transportation of all NFA items except suppressors and AOWs. If you are transporting other types of NFA, it's worth getting .20s for your suppressors and AOWs as well as a CYA. Many LE do not know AOWs and cans are exempt from .20s, and will wonder why they aren't on your approved list.
BATFE will approve a 5320.20 for suppressors and AOWs if you submit one.As far as notifying out-of-state authorities ... no notice is required to travel through a state -- that is protected under FOPA '86. Some states do have their own requirements for visitors, though, so if you want to shoot NFA at your destination, check in the hometown forums about that state's regs. (IIRC, Va., N.C. and Mass. regulate visitors' NFA, but don't hold me to that.)
source: AR15 Forums
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