My 2 new FAXON 5.56 AR-15 barrels are (too) overgassed ... sigh

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Quick update ...

I found some time to re-assemble (to the appropriate project point level) those two Faxon-barreled Uppers and, a couple of hours ago, fired 5/ea of the same Lot of ammunition thru them.

The ejected cases look unremarkable ... just as they should have the first time I did this testing.

Upon inspecting the cases I did notice a couple of things of interest to me.

The 20" sports a regular gas block (GB) and the 16", an adjustable gas block (AGB).

The cases from the 20" (rifle-length gas) are well-marked by the extractor and each has a tiny ding from impact with the case deflector.

The cases from the 16" (mid-length gas) are much less marked by the extractor and exhibit no case deflector dings.

Utilizing SWAG methodology, I had set the AGB on the 16" to a lower-gas position hoping to get it close to the point where it would successfully operate but not quite manage to lock back the bolt after the last shot ... and I got very lucky. All 5 fired & ejected but the bolt was not locked back. :) I plan on opening it in ¼-turn steps until I decide it is right.

Next step ... see if the FFHanguard on the 20", like the 16", will require modification for the AGB and make a plan to accomplish the mods prior to installing the AGB.
 
I thought the chamber clean up would fix the issue. The difference in your cases is probably due to the force of ejection, your extractor and gas pressure. The cases are most likely still good for reloading.
Glad to hear it's all working out.
 
??? What anomalies? :)

I have the gas dialed down on the 16" (needs to come up just a smidge) and the 20" is a bit energetically gassed for its particular system (the nickel boron BCG probably has something to do with that) ... which is why I am looking forward to installing the AGB that I bought for it onto the 20" and tuning the gas on that one, too.

BTW, when I installed the original regular gas block (the same one that I had used before) on the 20" for the test firing, I added a touch of anti-seize grease to both set screws. I did not want to have another fight with those silly things. Both broke & unscrewed very smoothly this time. :D
 
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