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This is gonna be interesting if the manufacture is undergoing another OMG moment right now. Lol
I am late to the game on this one as it appears that you have narrowed down the source of your problem. I have experienced something that was interesting a few weeks ago that I can share that may help people in the future.
I had an issue with the bolt not seating into the upper to close the upper onto a lower. I could not figure it out because everything looked GTG. Turns out I put an intermediate length gas tube on the middy barrel. The lengths are so close that I never noticed that I grabbed the wrong tube.
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Not really.
I don't have the good bolt - it belonged to a friend and he took it back with him. I can try to find a way to illustrate with the bad bolt... let me work on it and try to get some pictures. Its 5PM so I assume I will not hear from them today or through the weekend, which is disappointing.
Here's some pics of the bolt
Assuming that a edge of a piece of paper is straight, and using this straight edge to extend the line of the edge of the extractor, here you can see how much that line cuts into the top of the cam pin hole. comparing that to a good bolt should show you the amount it is off.
Here's two shots showing what happens when you drop the entire bolt carrier group into the upper and it comes to a dead stop on the barrel extension.
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Last edited by steelonsteel; 03-14-14 at 17:53. Reason: fixed pictures
The bolt and carrier are new, correct? Did you clean the bolt (removing tacky or old preservative oil), then lube it liberally (knowing the parkerizing on the bolt lugs may make for a tight fit in the extension, and the gas rings need lube as well -- explaining why it may bind in both carriers)?
Your carrier without bolt slides freely and butts against the barrel extension, showing the bolt carrier key doesn't bind on the gas tube?
From the pics man looks like a odd barrel extension. This is my wife's ar dry fitted.
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