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With or without barrel nut installed?
I think with a quality barrel nut and proper assembly you'll be fine. Try it and see. An old-timer trick was to fill it up with 242 before torquing but I wouldn't recommend that.
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A lot depends on the purpose of the build. If not for a precision build, then check for play with barrel nut tightened lightly. If no play then when the nut is properly torqued, you should be OK from a functional point of view.
If its a precision build with a barrel that is expected to be very accurate based on reputation, then I would do as you said, and go with a tighter fitting upper receiver.
Another option if you want to salvage this upper is to use a sleeving compound from Loctite, not the common thread lockers, to eliminate the space between barrel extension and upper receiver.
Mark
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Nope, the receiver's not scrap. Once the barrel nut is properly tightened, it'll work fine for your intended purpose.
I'm sure it'll work....but I wouldn't be happy about it. The wiggle certainly will not help accuracy.
I've always had perfect fit with Noveske uppers - no wiggle, but not so tight that it's a struggle getting the barrel on. BCM upper are VERY tight...they recommend you heat the receiver prior to installing the barrel to allow easier installation.
BTW.. BCM has blem uppers marked down 40% for black friday.
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