typical problems
I have seen many conditions present that can cause entry/exit problems for chokes. The situation that you describe seems to point to a defect in the thread area that causes a bind for much of the travel.
Sometimes a problem in the hole can cause a similar condition since it may force the tube to one side if there is a burr at the muzzle edge, for example.
If a tube is out of kilter, it may force the material to flex under tension until it clears a tight spot in the hole, and the one tube is far enough out of spec to uncover the condition.
I do not have faith in the factory installations of choke tubes since there have been too many examples in my shop for poor patterning and incorrect point of impact. Barrels that shoot off (worst personal example seen- 11" high @ 19 yards) cause uncounted disappointment, and my cure for such examples starts with a hacksaw and ends with a new straight choke hole installation.
A shorter barrel with a straight choke has got to be better than a longer barrel with a crooked choke. I figure that anybody that fails to understand that concept is beyond help, by me, at least.
I have seen and removed pounded chokes that were severely damaged by steel shot, and have converted many barrels (including classic shotguns) to safely and effectively perform with steel shot. Plenty of the shooters have told me that their buddies won't let them shoot first, anymore, and make them be the clean-up man, since their gun now has the longest effective range (after being modified).
I will add this one note, that your tubes all probably have small leftover burrs around the wrench notches. Every barrel that comes in my shop will typically get inspected for tube defects, at minimum. Many tubes have residual rollover burrs from the slotting cuts and can have parts of those burrs present in the thread area, or the barrel threads can contain thread burrs.
See the attached pictures.
One shows a rough spot and raised bit in the barrel threads.
Two shows leftover notch burrs and rough threads.
Three shows the internal notch burrs.
I hope this information adds to everybody's knowledge base.
[email protected]
Shotgun and choke specialist, trained gunsmith