SA80

Development

The idea dates back to the late 1940s, when an ambitious programme to develop a new cartridge and new class of rifle was launched in the United Kingdom based on combat experience drawn from World War II. Two 7mm prototypes were built in a bullpup configuration, designated the EM-1 and EM-2. When NATO adopted the 7.62×51mm NATO rifle cartridge as the standard calibre for its service rifles, further development of these rifles was discontinued (the British Army chose to adopt the 7.62 mm L1A1 SLR semi-automatic rifle, which is a licence-built version of the Belgian FN FAL).

In 1969, the Enfield factory began work on a brand new family of weapons, chambered in a newly designed British 4.85×49mm intermediate cartridge. While the experimental weapon family was very different from the EM-2 in internal design and construction methods, its bullpup configuration with an optical sight was a clear influence on the design of what was to become the SA80. The system was to be composed of two weapons: the XL64E5 rifle (also called the Enfield Individual Weapon) and a light support weapon known as the XL65E4 light machine gun.^[5]

The sheet metal construction, and the design of the bolt, bolt carrier, guide rods, gas system and the weapon's disassembly showed strong similarities to the Armalite AR-18 which was manufactured under licence from 1975 to 1983 by the Sterling Armaments Company of Dagenham, Essex,^{[6][7][8][9][10]} and which had been tested by the UK MoD in 1966 and 1969.^[11][10]

During the development of the SA80, a bullpup conversion was made of an AR-18 and a Stoner 63^[12][13][14] at Enfield due to the fact they could be used with stocks folded/without stocks which allowed the bullpup conversion and were later chambered in the experimental 4.85x49mm round. A bullpup conversion of the AR-15 was previously considered but the buffer tube in stock prevented the idea.^[15][16][17]

Technically, in the mid-1970s, the 4.85×49mm round was seen as superior to the then existing version of 5.56mm M193 round in use by the US (for the M16/M16A1) and by other forces. (This was the expressed view of trials team members whilst demonstrating the XL64E5 prototype at the British Army School of Infantry at Warminster.) It should be noted that development of small-arms munitions have a long and continuous life and it was estimated by the trials specialists from Enfield that this weapon would ultimately be superior in the 4.85mm configuration. For the 4.85 mm round, both propellant and projectile were at the beginning of their respective development curves. Also, weight for weight, more rounds of ammunition could be carried by an individual soldier – a considerable advantage on the battlefield. It was regarded as probable at the time that the argument for the 5.56 mm standard within NATO had more to do with the economics involved. Over the lifetime of a small-arms weapon type, far more money is spent on the munitions than the weapons themselves. If the 5.56 mm supporters had lost the argument in favour of a British 4.85 mm round, the economic impact would have been very large and political pressure undoubtedly played a part in the final decision.

Pictured left to right are the SA80-A2, XL 60 and EM-2

In 1976, the prototypes were ready to undergo trials. However, after NATO's decision to standardise ammunition among its members, Enfield engineers re-chambered the rifles to the American 5.56×45mm NATO M193 cartridge. The newly redesigned 5.56 mm version of the XL64E5 became known as the XL70E3.^[18] The left-handed XL68 was also re-chambered in 5.56×45mm as the XL78. The 5.56mm light support weapon variant, the XL73E3, developed from the XL65E4, was noted for the full-length receiver extension with the bipod under the muzzle now indicative of the type.^[19]

Further development out of the initial so-called "Phase A"^[19] pre-production series led to the XL85 and XL86.^[20] While the XL85E1 and XL86E1 were ultimately adopted as the L85 and L86 respectively, a number of additional test models were produced. The XL85E2 and XL86E2 were designed to an alternate build standard with 12 components different from E1 variants, including parts of the gas system, bolt, and magazine catch. Three series of variants were created for "Environmental User Trials". XL85E3 and XL86E3 variants were developed with 24 modified parts, most notably a plastic safety plunger. The E4's had 21 modified parts, no modification to the pistol grip, and an aluminium safety plunger, unlike the E3 variants. Lastly, the E5 variants had 9 modified parts in addition to those from the E3/E4 variants.^[19]

SA80 development was complicated from the start. One complication was at least three project staffing changes at the Royal Small Arms Factory, which resulted in repetition of testing several times. One problem with the design of the gun itself was that the cases would be ejected at constantly varying angles as it heated up and the rate of fire changed, resulting in a large ejection port.^[21] The conversion from 4.85 mm to 5.56 mm also caused a complication, as the rate of fire dropped dramatically as the gas port was left in the same position, but the pressure and time curve of the rounds were different. The 4.85 mm round was based on the 5.56 mm case in anticipation of the need to convert calibres. The barrel was changed easily, but the gas ports had to be enlarged considerably. This was made worse by the production of ammunition with power that gave a lower port pressure and rate-of-fire. Pressure problems had less of an effect on the LSW due to its longer barrel.^[22]

Production

The L85A1 GP rifle with a SUSAT scope attached to it

After receiving feedback from users and incorporating the various design changes requested, including adapting the rifle for use with the heavier Belgian SS109 version of the 5.56×45mm round and improving reliability, the weapon system was accepted into service with the British Armed Forces in 1985 as the SA80. The SA80 family originally consisted of the L85A1 IW (Individual Weapon) and the L86A1 LSW (Light Support Weapon). The first rifle was issued on 2 October 1985 to Sergeant Gary Gavin, a 26-year-old in the Worcestershire and Sherwood Foresters.^[6]

The SA80 family was designed and produced by the Royal Small Arms Factory at Enfield Lock. In 1988, production of the rifle was transferred to the Royal Ordnance's Nottingham Small Arms Facility (later British Aerospace, Royal Ordnance; now BAE Systems Land & Armaments).

A field-stripped L85A1 GP

In 1994, production was officially completed. More than 350,000 L85A1 rifles and L86A1 light machine guns had been manufactured for the United Kingdom. As responsibility for the funding and supply of the home defence regiments of the British Overseas Territories has been handed to the local governments of the territories (despite the regiments themselves coming under command of the national (British) government and being loosely integrated with the British Army), the SA80 was not automatically supplied to these units. The Falkland Islands Defence Force instead adopted the Steyr AUG while the Bermuda Regiment (since 2015 the Royal Bermuda Regiment) adopted the Ruger Mini-14 in 1983 (although it has held small stocks of the L85A1 and L85A2 since the 1980s for the purpose of familiarisation training as many of its personnel attend courses or attachments in Britain). The Royal Gibraltar Regiment, which is more closely integrated into British Army, adopted the SA80. In 2015, the Royal Bermuda Regiment replaced the Mini-14 with the L85A2.^[23]

The L85 is also in use with the Jamaica Defence Force.^[24]

The first images of the L85A3 prototype were unveiled on September 2016^[25] with working models on display on September 2017 at the Defence and Security Equipment International event.^[26]

Operating mechanism

With the exception of the L98A1, the SA80 system is a selective fire gas-operated design that uses ignited powder gases bled through a port in the barrel to provide the weapon's automation. The rifle uses a short-stroke gas piston system located above the barrel, which is fed gas through a three-position adjustable gas regulator. The first gas setting is used for normal operation, the second is for use in difficult environmental conditions, while the third setting prevents any gas from reaching the piston and is used to launch rifle grenades. The weapon uses a rotating cylindrical bolt that contains seven radially mounted locking splines, an extractor and casing ejector. The bolt's rotation is controlled by a cam stud that slides inside a helical camming guide machined into the bolt carrier.

Features

The family is built in a bullpup layout (the action is behind the trigger group), with a forward-mounted pistol grip. The main advantage of this type of arrangement is the overall compactness of the weapon, which can be achieved without compromising the barrel length, hence the overall length of the L85 rifle is shorter than a carbine, but the barrel length is that of an assault rifle. However, the adoption of this layout also means that the rifle must be used exclusively right-handed since the ejection port and cocking handle (which reciprocates during firing) are on the right side of the receiver, making aimed fire from the left shoulder difficult. This can also give rise to a tactical disadvantage when firing around the left side of cover, where the shooter must expose the majority of his body. However left shoulder firing can be achieved by tilting the right hand side of the rifle downwards, reducing the impediments of the cocking handle and the ejection port.

The SA80 family is hammer-fired and has a trigger mechanism with a fire-control selector that enables semi-automatic fire and fully automatic fire (the fire selector lever is located at the left side of the receiver, just aft of the magazine). A cross bolt type safety prevents accidental firing and is located above the trigger; the "safe" setting blocks the movement of the trigger.

The L85 rifle features a barrel with a slotted flash suppressor, which also serves as a mounting base for attaching and launching RGGS rifle grenades, attaching a blank-firing adaptor or a bayonet.

The weapons are fed from a STANAG magazine, usually with a 30-round capacity. The magazine release button is placed above the magazine housing, on the left side of the receiver. When the last cartridge is fired from the magazine, the bolt and bolt carrier assembly lock to the rear.

The weapon's receiver is made from stamped sheet steel, reinforced with welded and riveted machined steel inserts. Synthetics were also used (i.e. the handguards, pistol grip, buttpad and cheek rest were all fabricated from nylon). A Picatinny railed handguard was also developed for the type.

Sights

View through a SUSAT sight.

Rifles used by the Royal Marines, British Army infantry soldiers (and other soldiers with a dismounted close combat role) and the RAF Regiment are equipped with a SUSAT (Sight Unit Small Arms, Trilux) optical sight, with a fixed 4× magnification and an illuminated aiming pointer powered by a variable tritium light source (as of 2006 almost all British Army personnel deployed on operations have been issued SUSATs). Mounted on the SUSAT's one-piece, pressure die-cast aluminium body are a set of back-up iron sights that consist of a front blade and small rear aperture. Rifles used with other branches of the armed forces when not on operations are configured with fixed iron sights, consisting of a flip rear aperture housed inside the carrying handle and a forward post vertical blade foresight, installed on a bracket above the gas block. The rear sight can be adjusted for windage, and the foresight—elevation. In place of the SUSAT, a passive night vision CWS scope can be used, and also—independent of the SUSAT—a laser pointer.

L85A2 carrying upgraded Laser Light Module Mk 3 with 800 m range.

Weapons used by some Royal Marines, Infantry, RAF Regiment, Ministry of Defence Police and other soldiers with a dismounted close combat role in operations in Afghanistan have had the SUSAT replaced with the Trijicon Advanced Combat Optical Gunsight (ACOG).

In 2011, the Ministry of Defence began issuing ELCAN SpecterOS 4× Lightweight Day Sights (LDS) in an effort to replace ageing SUSAT units across the British Armed Forces, forming the first stage of the FIST infantry enhancement project.^[27] In order to mount the new sight, the weapon has been provided with an adapter to convert the existing sight rail to the Picatinny standard, in keeping with the updated handguard. The FIST project has also seen upgrades to the existing Qioptiq CWS (4×) and Maxi-Kite (6×) night vision scopes, and the introduction of the FIST Thermal Sight, following operational experience with the VIPIR-2+ thermal weapon sight in Afghanistan. All of the new FIST weapon sights have the capacity to accept Shield's Close Quarter Battlesight reflex sight.^[28]

Accessories

Bayonet attached to an L85A2 rifle. Note the barrel to the left.

The L85 is supplied with a sling, blank-firing adaptor, cleaning kit and a blade-type bayonet, which, coupled with the sheath, can double as a wire cutter (the sheath contains a small saw and sharpening stone). The rifle can be adapted to use .22 Long Rifle training ammunition with a special conversion kit. The Small Arms Weapons Effects Simulator can be used on the L85 when in training with blank ammunition. The rifle variant also accommodates a 40 mm under-barrel grenade launcher such as Heckler & Koch AG-36 40 mm grenade launcher variants.^[29]

L85 Rifle

A Royal Netherlands Marine Corps captain fires the L85A2

The L85 IW ("Individual Weapon"; formally, Rifle, 5.56 mm, L85A2), is the standard rifle for the British armed forces.^[30]

On operations with ground close combat units (Infantry, Royal Marines, RAF Regiment), the rifle is often fitted with an LLM01 Laser Light Module.^[31] The L85A2 can also mount the L123A2 UGL^[32] 40 mm underbarrel grenade launcher (British variant of the H&K AG36). The addition of the underbarrel grenade launcher adds another 3.30 lb (1.49 kg) to the L85A2's weight.

Royal Marine with L85A2 with Picatinny rail

Magazines issued with the L85A1 were aluminium, and not very robust. There are now three types of magazine issued with the L85A2, the most recent being the plastic Magpul EMAG purchased as an Urgent Operational Requirement (UOR),^[33] the other two are of steel construction with a stainless steel follower. The main variant is for live ammunition, and the other is exclusively used for blank ammunition. The blank variant is identified by yellow stripes on the magazine, and is designed to prevent the unintentional loading of live rounds. This magazine has less internal length so that live rounds will not fit, while still fitting blank rounds, which are shorter. Blank rounds will fit into the live-round magazine, but the difference in length increases the chance of a jam.

From 2007, an upgrade including the provision of ACOGs, a new handguard incorporating Picatinny rails (with optional hand grip/bipod),^[34] and a new vortex style flash eliminator is being introduced for use by selected units.^[35]

L86 LSW

L86 LSW

LSW during training

The L86A1 LSW ("Light Support Weapon") is a magazine-fed squad automatic weapon originally intended to provide fire support at a fireteam level. Its barrel is longer than the L85A1 and has a shorter handguard with a support stock with lightening holes protruding from the front holding a bipod. The stock has a shoulder strap and rear vertical grip. The weapon is otherwise identical to the L85 version on which it is based, and the same 30-round magazines and sighting systems are used. Like the L85 rifle, it has a selector on the left side behind the magazine housing, enabling either single shots or automatic fire.

The increased barrel length, bipod and the optical performance of the SUSAT give the weapon excellent accuracy, increased muzzle velocity and greater effective range. From its inception, the L86 was a target of criticism on much the same basis as the L85. The LSW has the additional issue (shared by any light support weapon derived from a rifle, for example the heavy-barrel FN FAL) of its inability to deliver sustained automatic fire as it lacks a quick-change barrel, and belt feed.^[36]

For a time, the primary use of the LSW shifted to that of a marksman's weapon within many infantry sections, capable of providing precision fire at ranges of over 600 m;^[37] however, it was replaced in this role by the Rifle, 7.62 mm L129A1.^[38] The role of a light support weapon is instead filled by the L110A2 Light Machine Gun (FN Minimi), which is a belt fed weapon with a quick-change barrel.

The L86A1 was upgraded to the L86A2 at the same time as L85A1 rifles were upgraded to L85A2 standards, undergoing the same set of modifications.

The L86A2 will be removed from service from the summer of 2018.^[39]

L22 Carbine

(left) L22 carbine variant as used by an aircrewman.

There have been three attempts at a carbine version of the L85. The first was in 1989 (length overall 556 mm, barrel length 289 mm). The second attempt, which was in 1994, used the standard L86 LSW handguard and a 17.4-inch barrel (length overall 709 mm, barrel length 442 mm). The third attempt (2003–2004) is also the only one to officially be adopted – the L22. This resembles the 1989 model but has all the necessary A2 upgrades, and has a 318 mm (12.5 in) barrel and an overall length of 585 mm. Around 1,500 were "manufactured" from surplus L86 LSWs; more were built with the increased demand. Due to the shortened barrel (12.5 in), it is less accurate and less powerful, especially at long ranges. Because there is no handguard, these guns are outfitted with a vertical front grip. It exists only in A2 variants as they were made to A2 standard.^[40] Initially issued to tank and armoured vehicle crews for emergency action out of vehicle, the L22 has been seen in the hands of the Royal Marines Fleet Protection Group and pilots of all three services due to its compact size.

L98 Cadet General Purpose Rifle

Cadet with an L98A1 GP

The L98A1 Cadet GP Rifle was a general-purpose (GP) rifle used by the Combined Cadet Force and Sea, Royal Marine, Army Cadet Force and Royal Air Force Air Cadets in the United Kingdom. It was introduced in 1987 to replace the .303 Lee–Enfield No 4 rifles and .303 Bren guns used for weapons training. The L98A1 rifle began a phased decommission in early 2009 and is now no longer in use. UK cadet forces have now received the updated L98A2 rifles. The L98A1 was similar to the L85A1, but lacked the gas components. It was a manually operated, single-shot rifle, with a cocking handle extension piece mounted on the right side of the weapon, and was cocked with the right hand. It was also fitted with adjustable iron sights. The L98A2 has the same gas parts and cocking handle of the L85A2, but lacks the selective fire switch. This means the L98A2 can only be operated in the semi automatic mode but is the same in all other ways.

Design flaws

Soon after being adopted for service, problems began to surface:

…the first five years of this rifle's service have been disastrous. A number of manufacturing defects showed up in service conditions, and it was not until the closure of the RSAF at Enfield and the setting up of an entirely new production line, with new computer-controlled machine tools, at the new RSAF Nottingham, that the quality of the production weapons began to improve. It will take some time for the poor reputation gained by the initial issue weapons to be overcome; the only consolation is that the same sort of thing has happened to other military rifles in the past, and they have managed to live down their early reputation and prove their innate reliability. It is to be hoped that the L85A1 will do so as well.

— Ian V. Hogg, 1990^[22]

When the L85A1 and L86A1 were first sent into major combat during the Gulf War, individual performance was appalling. The L85A1 proved unreliable in semi-auto mode, and slightly better in full-auto, while the L86A1 performed the opposite. Specific complaints included: the poor quality plastic furniture fell apart and the gun was damaged easily; the magazine release catch was easily knocked accidentally and dropped the magazine; the catch on the top cover over the gas mechanism was too weak and constantly popped open, so it had to be taped down; only 26–28 rounds could be loaded in a magazine because the springs were weak, and it also had to be kept very clean and the lips checked for dents; the LSW had a small magazine capacity for its role and overheated after 120–150 rounds fired in bursts; the weapons were difficult to strip and reassemble, with the gas plug easily jamming in place and requiring an armorer to remove; and ergonomic issues related to the safety catch, cocking lever, and the location and stiffness of the fire selector switch.^[22]

The SA80 initially gained a poor reputation amongst British soldiers as being unreliable and fragile, a fact picked up by the UK media,^[42] entertainment industry,^[43] and members of the House of Lords.^[44] The writer and former soldier Andy McNab said in his book Bravo Two Zero that the British Army procured a "Rolls-Royce in the SA80, albeit a prototype Rolls-Royce".

Immediately after the first Gulf war (Operation Granby), the UK Ministry of Defence (MoD) commissioned the LANDSET Report (officially entitled "Equipment Performance (SA80) During Operation Granby (The Gulf War)"), into the effectiveness of the L85A1 IW and L86A1 LSW.^[45] This report criticised the acceptance of the weapon into service. Neither weapon had managed to pass the sand trials and both frequently jammed. The mechanism of both weapons needed to be well lubricated as the weapon became prone to seizure if fired "dry", yet in sandy condition the lubricated weapon became unreliable due to the lubricant attracting sand into the moving parts. The LANDSET report identified in excess of 50 faults, most notably the magazine release catch, which could easily be caught on clothing and therefore accidentally release the magazine; the plastic safety plunger which became brittle in cold climates; and firing pins that were not up to repeated use, and prone to fracture if used in automatic fire mode. Although this report identified over 50 faults, and some of the rifle's problems were corrected as a result (e.g. the magazine release guard and trigger), these modifications addressed only seven of these issues and complaints over reliability in service continued.

The Ministry of Defence applied various minor fixes to problems in the guns or simply denied that a problem existed. The MoD finally began to address issues with the SA80 family in 1992 but procuring entirely new weapons was considered too expensive.^[22]

L85A2 improvements

As a result, a more extensive modification programme was executed. In 2000, Heckler & Koch, at that time owned by the British defence conglomerate BAE Systems, was contracted to upgrade the SA80 family of weapons. Two hundred thousand SA80s were re-manufactured at a cost of £400 each, producing the A2 variant. Changes focused primarily on improving reliability and include: a redesigned cocking handle, modified bolt, extractor and a redesigned hammer assembly that produces a slight delay in the hammer's operation in continuous fire mode, improving reliability and stability. There were equivalent LSW and carbine modifications.^[36] The British Ministry of Defence describes the L85A2 revision as "modified in light of operational experience ... the most reliable weapons of their type in the world".^[46] Armed Forces trials indicated extremely good reliability over a range of climates for various operational scenarios, though with a decline in reliability in hot, and especially hot and dry conditions.^[47]

The L85A2 has achieved an average reliability rate of 25,200 mean rounds between failure, and the L86A2 achieved 12,897 mean rounds between failures. Both weapons have higher reliability rates in cold/dry, temperate, and hot/wet conditions (over 31,500 MRBF for L85A2), but lower rates in hot/dry environments. The minimum expected life of A2 components is 10,000 rounds, meaning they may never suffer stoppages during their lifetimes. The L85A1 was required to be able to fire 120 rounds over 24 hours, and the L86A1 was required to fire 800 rounds in 24 hours. The L85A2 is required to fire 150 rounds in 8 minutes 40 seconds, and the L86A2 is required to fire 960 rounds in 36 minutes. The first A2-style SA80 weapons were rushed into action in Afghanistan in December 2001, and all 200,000 were converted by February 2006. Three to four thousand weapons were converted per month. Despite the modifications, reports started to emerge that the L85A2 was still jamming. In reality, there were few jams and problems that were much less serious than they were made out to be, stemming from isolated cases of soldiers not cleaning their weapons correctly.^[22]

The modified A2 variants are distinguished by the "HK A2" marking on the top of the weapon just forward of the buttplate and the distinctive comma-shaped cocking handle (shaped to aid the ejection of the empty round casing and prevent stoppages). A forward Picatinny accessories rail supplied by Daniel Defense was incorporated from 2008. The Magpul Industries polymer EMAG magazine was introduced from 2011 to replace the Heckler & Koch steel STANAG 4179 magazine.^[48]

Continued testing of the L85A2 in adverse conditions demonstrates its reliability over contemporary rifles, including the M16. Although it is heavier than most conventional and more modern bullpup rifles, its full-length barrel gives higher muzzle velocities and better terminal performance than both the M4 and the M16. Rounds from an M4 will only reliably fragment out to 50–100 metres, while the L85A2 and M16 allowed fragmentation out to 150–200 metres and the L86A2 has an even longer fragmentation range.^[22] Despite these modifications, the L86A2 did not overcome efforts to replace it with a belt-fed machine gun. British troops were issued with FN Minimi machine guns to add suppressive fire out to 300 metres; despite these officially being supplementary weapons, they all but replaced the L86.^[22] The 7.62mm L129A1 was issued to provide increased terminal effect at long range, to compensate for the limitations of both L85 and L86 weapons.

L85A3

The L85A3 variant was first officially presented in 2016. The changes from the L85A2 design include a modification to the upper receiver and a full-length rail system for optional add-ons such as a vertical foregrip, laser pointer and torch.^[49] It also includes a weight saving of 100g and a more durable hardwearing coating. The project received an initial investment of £5.4 million and will see 5,000 weapons upgraded initially, with plans for more weapons to be upgraded in the future.^[50]