Failure to Eject due to excessive gas port, UPDATE: Problem solved w/custom gas plug

[DeanD]

Ok, this is what I did, instead of plugging and re-drilling the barrel I made a threaded insert from an 8-32 set screw. Shortened it so it was .005" shorter than the distance from the barrel interface surface to the gas tube hole in the FSB. The existing hole in the FSB is about perfect for threading for 8-32. Drilled a .063" hole in the plug which is what everyone seems to say is the right gas port hole for a 16" carbine barre. Screwed the plug in and lo and behold we have a .063" gas port and it didn't cost anything and only took about a half hour to do. Didn't have to buy an expensive adjustable gas block, got to keep my A2 front sight, the fix is permanent nothing to get out of adjustment. BTW I crushed the threads on the plug slightly so it would screw in nice and tight and won't come loose. Can't go down of course because of the barrel but don't want it unscrewing into the gas tube. I am going to be out of town for a week so won't have a chance to shoot it for awhile but will post followup when I do.

The plug with .063" hole:



Tapping the gas hole, I did have to open up the bottom hole a little to get the tap in:



Screwing in the plug:



Job is done! The allen wrench hex is larger than the .063" hole so that just helps to ensure there is no mismatch from the barrel to the hole in the plug.