So,

I thought I was really rolling, got all the parts together, and I cannot get the bolt all the way back, it sticks in the buffer tube.  If I unscrew the tube I can get it out, it is only slightly out of alignment.

Is there such a thing as an oversized buffer tube??
The only option I can think of is to drill it out and JB weld a tube in, but is there some other fix?

thank you

Richard

I have never used JB,  but had some customers do that  they said they had no problems ? your call

That'll work and is probably the easiest to do.

Another option, if you have the equipment/experience and enough material remaining on the tower, is to drill out the threads, and make an insert threaded for the buffer tube.  If you know a machinist, he could make one for you. If you have enough material around the hole, use a threaded insert. If not, JBWeld the insert in place. This is probably the best solution.

Another solution is to find an experienced aluminum welder and weld up the threads inside the tower, re-drill and re-tap.

Grind  or lathe turn the rear O.D. of the carrier down. The only place it makes contact with the upper receiver is on the flats by the gas key and on the two flats on the bottom of the carrier for the first couple of inches. Easiest fix.