Assuming that you are looking for a light weight build I would stay from the milled upper like Sun Devil. I would look for a Rock River 9mm upper ( I think that ADCO has had them in stock yesterday).
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I would think that a billit upper would defeat the purpose of light weight.
I'm not sure what BCM is using for a gas port, Project Featherweight is a RRA stainless 1x8 midlength 16" which was cut to 14.5", the gas port wasn't touched.
Most 'pencil barrels' are .625" (5/8"). Project Featherweight is .565" I believe .555" is about the lightest one should turn it to. The gas block seat was left at .750" so that a custom gas block wasn't needed.
-do the RRA 9m upper have a hole for the gas tube?
-can you take off the shell deflector deal thing on those 9mm uppers and allow for a full size ejection port?
-does someone else make a 556 picatinny upper sans forward assist?
Thoughts of a uber light upper, maybe put grooves in the bolt carrier like the scandinavian G-3 varients to allow a thumb/finger forward assist.
very cool. thanks for your reply gotm4. just another project to start!
:D