I feel that both of my issues were functional issues and not "fit and finish" warts. Both rough bores and a poor gas tube fit may cause a gas leak.
To be honest, it was my first DD product and I was a bit disappointed. It is a excellent design. The rough bores I felt were not as big of a deal as the loose gas tube hole. I tried two different gas tubes from two different vendors, both were loose. Both fit fine in Vltor and LaRue blocks.
I wanted to use the DD because I didn't want to dimple the barrel. Since the LaRue tube didn't fit over the DD block and due to the issues above I ended up making one dimple for the LaRue block that replaced it.
Chopping up a FSB is a fine plan if you don't ever plan on changing configuration back to a fixed front sight.
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