To answer your question re. expired 4457, technically the US CBP Form 4457 has nothing to do with firearms in particular. It is a “Certificate of Registration for Personal Effects Taken Abroad.” Its purpose is to certify when you come back in the US that your personal effects were not purchased abroad and therefore are not subject to import tax or possible import restrictions. Many people use the Form 4457 to register expensive cameras, jewelry, computers, etc. before traveling abroad.
However, the South Africa Police Service interpret the Form 4457 as a "rifle permit" based on the rationale that if you were not allowed to own the firearms in the US, the federal authorities would not certify that you own them in the US.
Therefore, because South Africa Police interpret the Form 4457 as a "rifle permit" (which it is not in US law), they require a Form 4457 that is not "expired" (even though they do not expire in US law). Period. Attempting to use an "expired" Form 4457 is simply inviting potential disaster. It is just not worth it... ![E Nono :E Nono: :E Nono:](/styles/default/xenforo/smilies.original/e-nono.gif)
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Without knowing your circumstances, it seems that you have plenty of time to get a current year Form 4457 in the US, and a pre-approved SAPS 520.
To obtain a current year US CBP Form 4457, you need to download the template at
https://www.cbp.gov/sites/default/files/assets/documents/2017-Jun/CBP Form 4457_0.pdf , fill it, and you need to physically bring your rifle(s) to the US Customs & Border Patrol office at the closest international air/sea/land port where they will check that the serial numbers on the rifle(s) match what you list on the Form 4457, and they will stamp and sign the form. This is free.
To obtain a SAPS Form 520, technically you can fill up the paperwork upon arrival at the Police Station inside the Johannesburg International Airport, but there are long lines, and this can be a stressful experience. It is a much better idea to obtain in advance a pre-approved SAPS 520 and to have someone walk you through the process and get you to the front of the line...
A number of South African firms such as the Afton Safari Lodge (
https://www.aftonsafarilodge.com/) or Rifle Permits (
http://riflepermits.com/) specialize in helping hunters obtain pre-approved temporary import permits for their rifle(s), and provide “meet & greet” services at the airport. As of 2019, Afton Safari Lodge charges $100 for a pre-approved SAPS 520 and a standard “meet & greet” service at International Arrivals at the OR Tambo International Airport in Johannesburg. This includes walking you through the custom and police processes and checking you in for your connecting flight if any.
You can download the SAPS 520 Form at
https://www.aftonsafarilodge.com/wp-content/uploads/2018/07/SAP520.pdf . The form is long and daunting at first look, but your selected South African rifle import assistance firm will provide you with a sample of a completed form to use as a guide when you fill yours. Fill up the relevant fields on pages 2, 4 and 5, and sign page 6 in two different places.
The SAPS 520 is also the document that allows you to import your ammunition. You need to list on your SAPS 520 how many rounds you intend to bring for each caliber (maximum allowed 200 rounds per caliber). You can only import ammo for the calibers of the rifles listed in your SAPS 520.
Whether you bring your rifle(s) or not is a very personal decision. The cost of rental and ammo is often high, and the quality of the rifle & optics and ammo vary a lot from camp to camp. To use my own rifles is an integral part of my pleasure, so, to this day, benefits still outweigh constraints, but it is indeed one more thing to worry about...
I hope this helps. Enjoy your hunt