Spyder, I am involved in my second build right now. Waiting on the receiver to arrive. They can become a bit of a bitch, but can also be pretty simple. Not as easy as an AR, but pretty close.
Problem one is headspacing. There is a locking shoulder that goes into the upper that by it's width determines the headspace. There are a few different sizes of these, and it gets staked in once it's set. Your individual barrel, bolt/carrier, and upper all contribute to which one you will need.
Evildogs kit is metric, so this is not an issue. But just to make you aware for the future. If you get a British L1A1 kit, you will probably need a special sized breeching washer to get the barrel to index correctly to the receiver. (on a FAL the upper is the "gun" part.) If it is an Israeli, Argentinian, or some other Metric kit, you will not have this issue.
There are some differences between "Inch" and "Metric" pattern guns, too much to go into in this long post, but there is a lot of interchangeability. Metric is the preferred route for many, and gets you the cheaper, more popular magazines. Lot more of those out there, and a lot more replacement parts.
If you don't have a set of 7.62mm gauges, barrel wrench and receiver block for the vise, this might be a task you want to farm out. There are a number of guys that will do the hard parts for you. here is one, and he's cheap.http://www.cgwgun.com/FAL-Turn-Key-Upper-Assembly.aspx
Another guy who I am looking at for my project is Randy Kline: firstname.lastname@example.org
he will do the same above for $185 plus shipping, and has a real good reputation. Plus he will not discriminate on what upper you have. (There is discriminatory issues among FALers, Centruy, and Hesse will get you looked down upon)
Now the easy, but tricky part. Since to comply with govt. regulations you must have no more than 10 foreign parts. But that is not hard to do if you choose that route. Now just about every kit gun I've ever seen at the range or gun show has not been in compliance, your call. There are a couple of good vendors will supply you with American made replacement parts. Some of this stuff is easy, trigger, hammer, sear, mag. floor plate, mag follower, mag body, pistol grip, hand-guard, butt-stock, flash hider, gas piston, all count. Now for the good news, if you decide to just use the parts in your kit, and say fuck the govt regulations not only are you not alone, but rulings have shown that the rifle is not considered assembled until you put the magazine in. So there, you can test fit everything except the magazine and still be legal. Not saying that even the brightest beat cop you run into at the range will know jack shit about this, if he even has a reason to ask about your gun. This is probably an area where if they are getting you for something else, they could pile on charges relating to your project gun if they find it.
Other than one specialty tool used to take the spring out of the stock, you really don't need anything out of the ordinary. For that tool, I made one myself using an old deep well socket and a long "T" handled allen wrench. Just don't try to unscrew it with a flat head screwdriver, you will launch the end bolt and both springs across the room if they don't bounce off your face first.
Your first place to look is http://www.Falfiles.com
, join up there and they will not misdirect you.
For new receivers,http://www.dsarms.com/FAL-SA58%20Upper% ... oducts/13/
(falfiles members get a discount)http://www.coonaninc.com/index.php/cPath,7http://www.entreprise.com/receivers.html
Check the boards for used ones. (The one I am getting is used, but <$200)
For New Parts, in no particular orderhttp://www.falconarms.com/xcart/home.phphttp://www.gunthings.com/http://www.sarcoinc.com/rifles.htmlhttp://www.dsarms.com/
Don't worry about the lower being able to go into full auto, it's a quark with the FALs and is not an issue with the ATF. It tends to freak out AR guys who think the thing is illegal and will slam fire. The upper has to be cut in a manner to allow a safety sear to be installed before the gun can be considered verboten. (If interested in those mechanics, you can usually find demilled FA uppers for around $30 that allow you to see the difference and understand the operation) Some guns came into the US with those cuts legally, and now bring a premium ($5K), but you can't legally change out the ejector block and put in a safety sear without a lot of paperwork and a real good excuse.
My Advice, You can do it man!!!(best Adam Sandler "Water Boy" accent) Good Price on a kit, and you might end up with a good battle rifle
that is a shooter for $400-500.
Oh did I mention after you commit to buy the kit from evildog, go join http://www.falfiles.com
Good to see you back posting BCB.