@MSCHRIS
I hate to ask this but are you operating the bolt catch lever properly?
You said it works on an empty mag so the bolt face where it contacts the catch should be fine.
Get a light to see inside through your dust cover while you pull the BCG back with the charging handle. Try to push...
Best of luck, I would still get some extra gas rings and check on some of the things the other gents have suggested. You never know how many rounds were put through it.
I just finished another 308 build and put in a JP silent captured spring in it. I haven't had a chance to test it yet but it...
About a half inch I believe, it was a quick fix without having to mess with buffer weights. I still replaced the buffer weights eventually to tune it properly.
I had a similar situation buying a rifle off the ODT. Dude was shooting it suppressed as well. He was running a hefty spring and buffer and I just clipped alittle off the buffer spring and problem solved!