3)What's the barrel profile of your standard 10.5 inch Commando (this rifle will get SBR'd one day)?
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Regardless of the barrel profile, I'd vote against a 10.5" barrel now if the sole motivation is making it an SBR somewhere down the road, but a usable rifle now.
1. Having both, the 16" is much more practical (if you must have the length, it might as well be barrel) I admit I like the looks of a 11.5+5.5 FH XM-177-look-alike, but the required legal overall length requires giving up velocity for no overall length advantages, not to mention not an ideal first AR.
1a. I beleive J&T offers a 14.5 chrome lined with permanent Phantom FH for 16" overall.
See
You asked for em, we've got em.. Chrome lined LW & HBAR's for options/ prices. The 14.5+Phantom fills the coolnes factor of the Commando nicely IMO.
2. For it to be legal pending the SBR route, the 16" overall length must be permanent, meaning a
fixed flashhider. Removing it later may be just as expensive as a new barrel, depending on how the mfg permanently attaches it, and you'd still have a used barrel.
2a. Unless you are very familiar with the ATF requirements for making the FH "permanent" I wouldn't recommend doing it yourself; the penalty is the same if you get it wrong or try to slide by with loc-tite (to make it easier to remove later) -- 10 years.
3. Factoring the cost of removing the permanent 5.5 FH for an SBR vs. a new 10.5" barrel, keep an eye out for cheap upper receivers and build a new SBR upper AFTER the Form 1 is approved. That way you have the 10.5 upper and the longer 16" upper -- kind of a dual role carbine availability.
Cheers, Otto