just finished putting together a3 upper.
problem: can't pull the charging handle back
sometimes not all the time though.
weapon fires and cycles fine when you can get
the charging handle back to load the first round
any suggestions?

Does it come back at all or not at all?

With the dust cover open can you put your thumb in the recess of the carrier and move the carrier back at all?

Split the upper and lower.  Is there any abnormal wear at the receiver extension (buffer tube) area?

Does the bolt move in and out of the carrier easily?

If every thing seems normal here then try splitting the upper and lower.

Put the bolt/bolt carrier into the upper all the way with kind of a fast push.

Try to pull it out with the charging handle.

If it's stuck pretty hard you may have to drive it out with a wooden block and a hammer.

If that's the case check gas tube alignment in your upper.  Get some lamp black or site black and spray a little around the exposed part of the gas tube in the upper and put the bolt carrier in again.  Did any rub off?

Try inserting just the carrier with the bolt in it.

Still stick?

answers in order:
if it comes comes back it comes all the way back.
no.
no.
brand new chrome bolt smooth but slightly tight.
comes out.
non-collapsible carbine stock
any suggestions?

Halfcocked and J3_ thanks for all of your suggestions
went over rifle again and damned if i
don't believe it but i think you hit it right on the head J3_ .
now if i could only figure out how to post pics
              thanks again guys that was fast

i'm having this same problem with the new match gun i'm putting together. what did you come up with to fix it?

jp3:

1. your posts seem to disappear after a few days, what's up with that?

2.my problem isn't the car stock. this gun has an a2 stock.

it seems my problem is the lack of a barrel. the charging handle is getting beaten up by the bolt carrier slamming into it at the end of its travel instead of locking against the chamber. i figured this out when a bolt carrier/charging handle combo from one of my other guns was installed and the charging handle broke off after letting go of it. so now i need a barrel and a pair of charging handles. :)

cheers,
Sam