Do you use it the way the instructions say to or do you put a piece of square 1/2 inch steel rod in it and then clamp that in a vice?
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Prime example of the Brownells Reaction Rod. > http://www.ar15.com/forums/t_3_4/684...14178#i7014178
So, it's obviously a no-no to clamp the upper in a vice directly on the forward assist and rounded left side. However, I always just clamp mine between the bottom of the upper and the rail. I have zero issues applying the specified toque to the barrel nut with that setup. For soft jaws I use either wood or UHMWPE (cutting board material). This isn't my photo, but it might as well be - same HF vice, same white plastic blocks:
http://kevinholman.com/byor/ar10nove...perclamped.jpg
Also, when removing a barrel nut, always heat it up first! Just an electric heat gun is fine if you're squeamish with a torch. Warming the nut directly expands it, and also loosens/softens anything binding the threads.
He started out with a DPMS Claw vise block, isn't it possible that it was the culprit? But yeah I can see how torqueing from the rod end could do it. I still think the Geissele rod would not be an issue with in spec torqued barrel nut, 80lbs seem excessive even for removal. Have you seen the same thing happen with Geissele rods or is it just the Brownells type?
The DPMS Claw block sucks too but all of the damage being on the left side of the index pin notch indicates that it was the Brownells tool that caused the index pin to shear.
Because of it's popularity I have seen this type of thing happen many more times with the Geissele Reaction Rod, both with installation and removal of the barrel nut but mostly on removal.
Prime example of the vise block.>>> https://www.ar15.com/archive/topic.h...&f=49&t=355495
I am a woodworker/gearhead so I whipped up wooden fixture with a 1/2" drive T-handle sandwiched between it clamped to the bench. Working with the upper parallel to and close to the bench doesn't require 3 hands like doing it the Brownell's way. Like I said... I would have the Geissele rod if I did it everyday.
http://i1058.photobucket.com/albums/...&1447365177435
http://i1058.photobucket.com/albums/...&1447365348978
Better than doing it as per Brownells instructions for sure.