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Ar gas issue...i think.

Did you verify gas key/port is unobstructed with bolt removed?
Take the bcg out of the rifle, flick it out so the bolt is fully extended and stand the entire assembly up on the bolt face and let it free stand. If it collapses the gas rings are shot or are incorrect size.
Does it pass the "flick test" ?

Are you running it wet?
As far as i can tell theres no obstructions. I had light come through with a flashlight. It does not collapse when stood on end but the gas rings do seem too big to me. I do run my guns on the wetter side.
 
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What brand/model of BCG?

Does the combo of “bad” BCG and “good” charging handle work?

Not sure that a gas key can be “overstaked”, unless it actually damages the part to the point that it won’t go in the receiver.

No pistons in a direct impingement AR. Is this a direct impingement AR?

Check the gas key isn’t loose.

Even if not loose, it could have uneven contact between the bottom of the key and thr top of the carrier.

I’ve seen well-staked keys where a screw was actually snapped off. You couldn’t tell because the staking held the screw head in place.

You could have an obstruction inside the key. Disassemble the BCG, get something like a short length of weed whacker line, insert it into the gas key, and make sure it comes out inside the carrier.

Gas rings worn or missing.

Poor fit between the bolt/bolt tail and the carrier. One of both could be out of spec.

Issues with the lugs not allowing the bolt to unlock smoothly.

Bolt cam pin dragging on receiver. Check for new wear inside the receiver.

Same ammo used for all comparisons?

When you had the malfunctions, and it ran fine, was the same magazine used?

I’m happy to look at it in person.
 
I was told PSA but there are no markings. Full auto profile.

Yes same malfuntion with the other charging handle.

Yes it is direct impingement

Passed weed eater string through, no obstruction.

I dont have a way to check for specs, tools coming soon.

There does seem to be alot of wear on the bolt lugs for just a few rounds.

No new wear on the inside of the of the receiver.

I used federal xm193 and lake city green tips, same malfunction for each ammo.

No i started with a hexmag and then switched to a gen3 pmag.

I may take you up on that offer as in my small reservoir of knowledge i have no earthly idea.
 
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