Thanks, guys, that is a lot to think about and verify.
First things first, that barrel had to come off. After 125 rounds, wasting ammo was not going to help this rifle.
I don't think there was more than 50 ft-lbs of torque, and there was no hard start here. Just started twisting on my wrench and torque got less and less until the barrel was off. No threadlocker here, just a gummy rubber cement goo on the barrel threads.
As the barrel came off, goo and all. What the first pic does not show is scarring on the breech end where the bolt nose jammed against the barrel. This likely accounts for the hard as hades bolt lift with factory loads. You can see the raised goo on the breech end at the end of the bolt rotation. No polished radius on the chamber entrance as is critical when making an AR barrel - just sharp edge steel without burrs.
The 'scarring' on the barrel exterior is just aluminum smearing from my barrel wrench inserts that comes off with WD-40 and fine steel wool.
A bit of WD-40 and a wire brush. This is some of the worst machine work I've seen that I have not done myself.
The thread relief measured 0.260", the torque shoulder is as horrible as it looks, and the thread relief shank is 0.669" towards the breech end at the threads, and 0.638" diameter at the torque shoulder. I guess the huge "thread relief" is relief area for a threading die. That would explain the extra long receiver ring. Lowered machine operator hours per unit helps reduce costs per unit, but that silly scallop on the receiver looks to be more machine work than by not single threading this... Huh...
The reduced diameter area is 1.275" long, with 0.745" OD threads at what looks like 20 tpi (thread pitch gage missing somewhere). Believe it or not, but the barrel threads were a close fit to the receiver.
The bare receiver, ~1.205" OD IIRC, cleaned up with WD-40. There is a long barrel thread. Too bad the first 1/4" is wasted by the huge thread relief. The receiver looks to be of a higher machining standard than the barrel.
I am thinking of machining off that scallop on the front of the receiver face. It will help balance the length of the receiver ring and look better with my 1.050" round blank. I need to think that one through and make a mock up first.