The easiest way to deal with the barrel is to use one of our MicroTune Gas Blocks.
That includes the proper size port and the rear set screw always lines up.
Its not critical that the front screw be dimpled normally, but the front hole may need to be dimpled if it partially overlaps an existing dimple.
You can then easily drill and pin the block for a permanent install.
A slightly cleaner approach would be to install the Custom Tune Gas Port into a LaRue gas block.
This would take a little more effort, but the dimples will all line up perfectly.
Whatever option you choose, if the gas port is ~.090", you'll want to make sure to address the gas drive somehow.
We have a barrel that had a .093" port (16" mid Wylde chamber) and it would only function acceptably with brass .223 ammo.
It would rip the rims off steel case wolf and blow primers on XM855.
It runs great now with either a .076" or .073" port using a variety of ammo.


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