Outside of the recs to trash the entire gun and/or customer, easy button would be to tell your customer it’ll be cheaper to pick up a $100-$150 Rosco/Faxon/BA barrel from whatever retailer is the cheapest than to continue to pay you to unfuck someone else’s incompetence.
If you don’t want to do that, it would seem you’ve eliminated basically everything but the barrel/chamber/throat through everything you’ve done. Here’s a few steps I’d probably go next if it were me:
- Try different factory ammo (if you haven’t already). I wouldn’t say it’s super common, but you could have a bad batch/lot of factory ammo.
- Check COAL on stuck round vs factory round. If different, it’s potentially an ammo issue or a throat issue.
- Look for visual damage on a stuck cartridge. If there is any, it could point in a good direction.
- If not, cover a cartridge in sharpie (case and cartridge) and let the bolt fly. Anywhere you see shiny is something to look at and if it’s getting stuck, it should become visible using this process.
- If nothing from the above, drop a new and a stuck cartridge into a case gauge and compare. If the loading process is somehow damaging or deforming a cartridge just enough to cause an issue, this should become apparent here.
Until you’ve identified what is causing the cartridge to get stuck, it’s impossible to work on a solution, there’s just too many variables.