How much .22LR case bulge is normal for an AR?

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To clean my conversion kit I just take it down as much as I can without tools.

Throw it in the ultrasonic cleaner with water and 20% Simple Green concentrate. It comes out looking like brand new. I then blast it out with compressed air, hose it down with Break Free CLP, and reassemble.

Like others have mentioned, make sure the breechface is completely clean.
 
I had a similar problem with my Chiappa 1911-22 .22LR pistol. The chamber was defective and the barrel liner (which on that model contains the chamber) needed to be replaced.

How did you contact them? So far I've filled out two different of their online forms and haven't gotten any responses back. I cant say I'm surprised.
 
Update.

ATI sent me a new upper. Was actually a much faster turn-around than I thought. Sent it back on the 14th Jun, received the new on, 21 Jun.
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Back to plinking! Hopefully this one doesn't give me issues too.
 
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