I am starting my 1st build job, and rec'd an upper from M&A Parts.  Since the lower hasn't arrived yet, I put the upper on my complete Bushy lower and went to the range.  I noticed that the charging handle was real tough to work. After each shot, I had to hit the forward assist at least twice!  The bolt & carrier moved fine, up til the last 1/2 inch or so, then got real tight.

I only shot 25 rounds, but had to "assist" it almost every shot.  What gives?  Does it just need more rounds to break-in, or do I need to send it back?

Your gas tube might be misaligned.  This is a hard problem to catch if you aren't aware of it.

I would look at the gaskey and gastube relationship.  One smith showed me a BADLY beaten up gas key from a customer's gun.  That key must have battered the gastube out the front of the receiver.  

Thanks for the input.

As stated, check the gas key, and the screws to make sure they are tight and staked in place. Loose screws could be dragging against the upper. Also check the cotter pin on the bolt carrier, it can also drag against the upper.

Does the bolt carrier move freely when the upper is removed from the lower?

Yes, the bolt carrier moves fine, except for the last 1/2 inch or so.  It appears that the lugs are binding/very tight.

However I did go out & shoot another 25 rds and it cycled just fine.  Thanks

Recheck your gas tube, I just had one that was out a little and did what you are describing.