Quoted: that makes sense. Can anyone tell me what is involved putting the upper together from scratch. Will I be able to do this myself or will I have to involve a gunsmith.
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I assume that you mean getting a barrel, an upper, a gas tube, gas block, etc as seperate pieces and putting them together. It's really not that hard to do. I've heard a lot of different specs about the torque on the barrel nut (everything from 30 pd/ft to 160 pd/ft), but honestly, that's not as important as some people believe, just make sure that it's tight and then tighten it to line everything up so that the gas tube will go in place.
What you will need is a barrel wrench, a rollpin punch (a regular punch will usually work as well), and a small hammer. The pin punch and hammer are to tap the pin in place that holds the gas tube to the gas block. Depending upon what gas block you use you'll either have to tap it into place on the barrel or slide it in place and tighten it down, most likely with a hex head wrench. One thing to make sure of is that the gas port on the barrel is lined up with the port on the gas block. If you test fire it and the bolt doesn't move to the rear to chamber another round then that's most likely the cause.
If you'd like feel free to e-mail and I'll write you back with an answer as soon as possible. I'm not an expert, but I've built a few and I've got a diploma showing that I've taken a gunsmithing course on building and accurizing the AR-15.
Robert