I have had to cut off 5 gas blocks. The problem as I see it is a combination of the type of dimple being done, the type of screw (pointed set screw with serrations) and the Loctite.
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The last time I had to remove a set screw gas block installed by BCM, I had to drill one of the screws out. I tried everything, except for the un-cure IG mentioned. Whatever BCM uses, it might as well be concrete because they don't come out easy.
I had to destroy a self-installed gas block once when I stupidly stripped the set screw with too much torque on the Allen key. This was after Uncure and heat wasn't getting it done. I ended up cutting a slot across the screw with a bandsaw. That relieved enough pressure on the screw that I could use a flathead to get it out, after another round of Uncure.
BCM and Us (SIONICS) use knurled set screws that bite into the barrel plus red loctite. Its as solid as pinning a block. Oh wait, only pinned gas blocks are good.....
Weird... I haven't had a problem breaking set screws with Red Loctite loose... a little heat and they came off. Guess I was just lucky, perhaps.
Heck, I got one upper from BCM that didn't even have any Red Loctite on the screws, nor were they torqued properly. Always pays to check your equipment yourself, as the final QC.
Damn if the has blocks from BCM are this hard to remove / changed then I'll bet my BCM break on my BCM 14.5 is there 4 EVER lolo.
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Sounds like a common problem. I can see not ever having to remove your block, but if the need arises, is there any other alternative loctite formuler (sic) that isnt gorilla glue basically? The knurled set screws should help out alot?