The next major change occurred in 2003 when Ruger made a significant overhaul to the Mini-14 product lineup. These changes began with serial prefix 580; the updated rifles began to ship around 2005. The overall styling was improved, including the stock; however, there was a great emphasis to increase quality while developing new manufacturing methods to help keep production costs down. The sights were improved to feature a non-folding aperture rear and wing-protected front sight blade mounted in a barrel band. The single largest emphasis was to improve accuracy.
While there were several small technical changes that have helped to improve accuracy, by 2007 the barrels of standard models were increased to .530 inch diameter at the muzzle for improved rigidity. Ruger also introduced specialty models including a Tactical version with a flash suppressor; Tactical with a flash suppressor and folding stock; Target Rifle with a Hogue stock and harmonic barrel tuner; Target with harmonic tuner and thumbhole stock (recently discontinued) and many other variants.
Ruger Reinvents the Mini-14Today, Ruger operates many cold hammer-forge barrel manufacturing machines, and quality is generally good. The “cold” process serves to prevent warping during the forming process. Several sources also indicate that hammer-forged barrels offer longer life. Manufacturing its own barrels has also served to help Ruger keep production costs within check.
The Mini-14’s original design team was a talented mix of individuals including Jim Sullivan, who was the primary designer and is perhaps best known for his early work on the AR-15, Harry Seifried, who carried on Sullivan’s developmental work and Roy Melcher, who finally brought the Mini to market. Melcher, who was with Ruger from 1968 to 1987, came out of retirement in 2003 to rework the Mini and re-tool its production line. “I was surprised when I came back that original tooling was still being used,” he recalls.
Of course, Melcher knew the Mini was based on sound design principles—after all, he had seen some law enforcement Minis come back for service after they had fired as many as 100,000 rounds, and they still functioned. But he also knew that updated manufacturing techniques could only make the Mini better. “Instead of moving parts around, we applied the concepts of cells and lean manufacturing,” Melcher said.