i was thinking "bolt carrier too short" also, but since you measured it, i guess not.
for the sake of argument, assume the buffer retainer pin location is within spec.
then, the symptom is that the BCG is at rest too far forward. and the BCG rests against the barrel extension. so, is the barrel extension too far forward? on some handguards, the installation kit includes some shims that are kinda thick-ish in my opinion, those would move the barrel extension forward in the receiver, so the BCG is then more forward. is that what was used in this case?
or in that same vein, the front face of the upper receiver is out of spec and a little too long, resulting in too much length between the buffer face and the barrel extension.
i'm guessing something is off by 10 or 20 thousandths, that range.
grasping at straws.