Short stroking AR15, what am I missing?

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What brand were the other 3 barrels. Psa has bcg on sale for super cheap right now. I'd pick one up and give it a try. Worst case use it in your new upper. It sounds like your other barrels were probably overgassed so it masked the problem. BA barrel are conservatively ported. What brand is your bcg. Don't take this the wrong way, but from your parts list you've used the cheapest parts you could find and something doesn't work. Probably because one or two parts are out of spec.

The other 3 were a delton, a bergara, and a bear creek arsenal. Its a bear creek dual charging upper so the bolt carrier group came as a set with the upper. They were far from the cheapest parts I could buy but they are not premium parts either. The only cheap parts in the gun are the gas block and the forend.
 
I think i might have a couple spare gasblocks if you want them, im done building ars untill something new and interesting comes up...i know ive got a .625 dunno bout a .750
 
The other 3 were a delton, a bergara, and a bear creek arsenal. Its a bear creek dual charging upper so the bolt carrier group came as a set with the upper. They were far from the cheapest parts I could buy but they are not premium parts either. The only cheap parts in the gun are the gas block and the forend.
Were you using the same gas block with all the barrels?
 
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