It is more likely that the gas block was an issue than the barrel port itself, although anything is possible. This is the first Ive heard of getting a choice between the commercial port size and a smaller port size, usually < 0.075.
Last I checked, DD does not let people build their own rifles. Perhaps a DD dealer can chime in on the possibility of special-ordering a barrel with the smaller gas port size.
I know they are in the process of building, or recently built, a new facility, and hired an additional 75 workers.
I for one would spring for a mil-spec'd gas port MK18 upper.
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