Well, in Sharp's defense a headspace gauge isn't going to tell if there's something wrong with the interface between one or two bolt lugs and the barrel extension.
Maybe the OP needs to send his upper-or at least his barrel-to Sharp's and let them test things out with high speed cameras to see if they can figure out what's going on.
“The rifle itself has no moral stature, since it has no will of its own. Naturally, it may be used by evil men for evil purposes, but there are more good men than evil, and while the latter cannot be persuaded to the path of righteousness by propaganda, they can certainly be corrected by good men with rifles."
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