I'll be willing to bet, that if you remove it everything will be fine.
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i was about to suggest the same as grant. if the bolt is completely failing to pick up the next round, it might be outrunning your mag. see what happens. i'm not too familiar with the BAD lever, but have read about people having some issues. weather or not they were the same issue, i couldn't tell ya.
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I have seen one gun where the Bolt Catch locked the BCG back on the Bolt Carrier body and not in front of the Bolt Face. This caused a similar looking feed to what you have.
I can't get my rifle to duplicate catching on the BCG body, so it might have been a BCG issue.
Try using the BAD to catch the BCG by intentionally "miss" catching the Bolt but still applying pressure on the BAD to see if it can make the BC catch the front BCG shoulder.
Just a thought...
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It sounds like the new upper has an oversized gas hole to me. What weight buffer do you have, the h? Cheap to get a heavier one (h2) and try it out. I would loan you mine, but i'm in AZ. I know this video is for a piston setup, but I saw it on one of the topics the other day. Good cut out animations.
http://www.youtube.com/watch?v=2LltApvOC0U
skip to 4:27
it sounds like your problem to the T.
Most people are going to point to the BAD lever because... well they just will. Until you take it off and shoot the gun, and try the test Grant mentions, it's kind of pointless to speculate and it's going to be hard for people to get over the BAD.