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No issue if your AR is a preban w/ 16" or longer barrel.*

Presumably your AR has a pistol grip (1 feature already).

If you have a postban, then having a pistol grip + flash hider is going to make your gun in violation, regardless of whether the flash hider is welded on or not.

During the Federal ban, a threaded barrel with unpinned device = evil feature (not necessarily the device itself).

*The only thing having a perm attached flash hider does, on some guns is bring you up the minimum-nonSBR length (but that is a Federal issue first, then a state issue). This is an issue with 14.5" 14.7" and 11.5" guns that require appropriate length flash hiders to bring barrel OAL to 16".

If you are building a ban compliant rifle, and have pistol grip, then your muzzle attachment cannot be a flash hider or flash suppressor (welded or not) and it must also be permanently attached (soldered, or blind pined).
 

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All flash hiders are illegal on post ban AR's. Does not matter if they are pinned with weld over the pin or welded per BATF specs. Post bans have to have a Muzzle brake or a Comp that is post ban compliant. Some manufactures sell muzzle add ons that will come with paper work saying they are BATF post ban compliant. I recommend approved muzzle brakes/comps over ones that (look) like they are compliant but not stated. Then install it per BATF requirements.

consequence of an unpinned & welded flash hider? You may never have a problem all the way to bubba will be your room mate for a few years in a 9 by 12 cell!!!!
 

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So if I was to build an AR with a 16 in barrel- no flash hider only muzzle brake?
You would be ok, so long as you did not add an additional "evil" feature in place of the flash hider (like a collapsible stock, bayonet lug, or grenade launcher)

whats the diffrence?
Physically, the flash hider disperses the flash from the rifle so that it does not bloom and blind the shooter. Some have tried to cast a flash hider as hiding the flash from others, but that's simply not true. People around you can see the flash, particularly if you are shooting in their direction.

A brake redirects expanding gas up and and out to the sides so that the muzzle of the rifle does not jump. This should result in faster follow up shots. Whether it does and how much really depends on the caliber and particulars of the platform being judged. It also results in a louder gun and possibly more muzzle flash, as perceived by the shooter and particularly those to the sides and rear of the shooter.

It also sucks to RO guys with muzzle brakes.

Legally speaking, BATFE has ruled that flash hiders/flash suppressors have no "sporting purpose" and that's why you can't have them. Additionally, some flash hiders also serve a secondary purpose as an attachment point for rifle grenades.

If you are wondering, yes, gun owners made a strategic miscalculation by allowing the concept of a "sporting clause" anywhere near the 2nd amendment.

Whats a good choice for the muzzle brake?
See Gunner57's link.
 
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