Thanks Shivan. I wanted to give a quick update on this. First off I want to express my gratitude to AAC, especially Mike Mers @ AAC.
Mike took the LMT upper apart, and inspected the barrel, flashhider, threads, etc.
The response was that the flashhider was on absolutely straight (much to my relief, as I was worried I had borked that process up even though I followed instruction to the letter). Threads were spot on, barrel, etc. The overwhelming theory lines up with what has been said before, that a round may have been poorly seated in the casing, or a weak primer may have caused an under-powered round.
Either way, no baffle strikes, and just a small nick, resulting in a small bulge on the end cap. So this was not a fault of the AAC product, and in Mike's words, "just bad luck". I want to go on record thanking them for still offering to replace the end cap and make it look good as new.
Thanks again to AAC, and I appreciate all the advice I got here on this thread.
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