I have used Streamlights (TLR-1 and TLR-7 and 7a recently) for pistol/rifle lights for a long time, they always worked well and I've had no issues. I don't have any experience with the TLR-1HL.
I have recently switched to a Surefire 300A for my carry gun, based on reliability feedback from...
I have owned many AKs and honestly my PSAK103 folder is one of my favorites. CHF barrel, excellent fit and finish, American made, lifetime warranty, multiple time survivor of the AKOU 5k round torture test...one day folks will get over the undeserved internet hate for PSA AKs.
Ehhh, you might want to actually test this stuff, or watch folks that do. Forgotten Weapons on Youtube has a great series of Mud Test videos and the AK did NOT perform as well at the AR in them. The less sealed AK design allows for more ingress of mud which causes failures after a few rounds...
You'd lose lol, I'd strap that mfer in a weighted shooting rest and have a ball. You're talking about a shooter issue (flinching), not a brake making the gun more accurate. Why you'd want a gun setup like that I don't know...
Recoil has nothing to do with your group size, if you are applying proper shooting fundamentals. Muzzle devices can decrease or increase the size of your group (or move it).
The AR15 platform doesn't do well with 7.62x39 because of the size of the bolt face. The KS47 has far too many proprietary parts for my comfort. If you want .30 caliber in the AR15 platform, get a 300 blackout AR. If you want something in 7.62x39, get a good AK. You might not like it, but...
The bolt locks into the barrel extension. The barrel is definitely attached to the upper receiver via tension from the barrel nut. I've put together a few uppers before. You feel free to leave your barrel nuts loose, I'll be tightening mine to the proper torque spec.
As to the plastic upper...
Psh...I mean it's only the thing that holds your barrel in which contains an explosion 1 foot from your face and hands. o.O Eyesight and fingers are overrated.
Personally I'd put a red dot for an AK on Ultimak rail, also gives you a place to mount a light. Adds no weight over a standard tube and doesn't add girth to your rifle.
I've carried appendix for years and I'm no small guy either. This sounds like a holster problem, what are you using? I've used various kydex holsters w/ clips and such but now use snap loops to attach my holster to my belt. If you are having issues with it rubbing your shirt while driving, be...