I imagine that under a normal firing schedule, that is very probable.
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I don't think you'll have an issue, especially with the new NiB coated trigger. I have a 5 year old KAC trigger (older design) that has not given me any issues over several thousand rounds. In fact, it's only gotten better.
The reports of durability issues that I've seen have been limited to mostly second hand accounts on mil issued guns. I'm not saying that the issue doesn't exist, but those weapons were likely abused and saw a lot of extremely hard use. It's also possible that an end user may have attempted to adjust the trigger and subsequently screwed it up. The new design increases durability by application of an NiB coating and is non-adjustable, addressing the two most likely failure points.
I think it's important to remember that before Geissele came along, KAC was the ONLY suitable option for a mil issued match trigger. Before Geissele, the KAC 2 stage match trigger was the standard by which all others were judged.
I've owned both an SR-15 and SCAR 16S.
The SR-15 was very light. I had an early one and if I remember correctly it did require a little break-in, the bolt failed to strip a few rounds off a steel 20rd Colt mag. Also the front rail was canted requiring the windage on the rear sight to be cranked all the way to the right as far as it would go when I was zero'ing the irons.
Besides that it was a great rifle. I ended up selling it later in disgust when an idiotic gunsmith scratched the hell out of the barrel from removing my Triple Tap he installed upside down (with Rockset).
I also carry an M4 at work and while the ambi controls on the lower are nice, it didn't help with my muscle memory much when I was at the range.
After that rifle I bought the SCAR. Very nice rifle too albeit a little "plasticky". Would be very nice as something issued to me but for $2200+ the quality didn't completely feel all there.
The gas piston system was great too, reminded me a lot of my M1A. Very low maintenance rifle and after a day or two at the range cleaning felt optional.
I eventually sold that off as well because I was interested in getting an SBR and if I cut the barrel down on that I'd be stuck with it for good because nobody has come out with an aftermarket short barrel for it yet.
Ive owned several SR15's, and two SCARS, and I would also choose the Knights. I totally agree that while the SCAR's gas system is cool, FN screwed several key factors on that gun up. The first thing I posted online when the SCAR came out, was how poorly designed the front sight was. There's a reason why almost instantly Troy invested in manufacturing a solution to that very issue, and now you see FN addressed it as well on the newest SCAR iteration, the FNAC, I believe it is called. I won't get into the selector switch or the stock. Don't get me wrong though, the SCAR is worth owning IMO, if you already own several other key carbines/rifles first, most importantly, an SR15...
Anyhow, if the SR15 wasn't on the market, I would find a way to own a BCM Jack. Either buy one secondhand, build a clone, or wait for Paul to produce more.
Interesting, how long ago did the design change? Also, do you happen to know what the recommended maintenance schedule is with the KAC trigger (how often to replace hammer spring, etc.)?
One more potential issue, I have a ton of Hornady 75gr. TAP .223, this is the ammo I'd be using to zero the rifle in with. I know there was early reports of SR-15s not running well with .223 vs. 5.56, is this still an issue?
The SR15 is the pinnacle of AR carbines. It's everything the shorty AR is supposed to be and nothing that it isn't. FWIW, I run my SR upper on a Colt lower with "the block" and thus had to swap the full auto carrier with a semi carrier. No problems.