I'm not asking for a guarantee from anyone. I feel comfortable with the headspace now; I guess what I'm asking is if there are any other common problems with the Chinese barrels that would preclude proper operation.
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Understand that bolt replacement in an M14 type rifle is more than just headspace. You can get a good headspace reading with a gauge and still have a dangerous condition. BOTH your locking lugs on the bolt need to be in even contact with the receiver. An improperly fitted bolt may only be partially contacting on one lug, but still eliminate any wiggle and give you a good headspace reading. When you touch off that 50,000 C.U.P. .308 in there though, you could have problems.
That's why M14 bolts should be hand lapped to the receiver. To insure that both lugs are "fitted". This ain't an AR or FAL where you just swap out a bolt, check the headspace, and go blast. This is an old school design that actually requires fitting. Good headspace is only half of fitting a bolt to an M14.
Your bolt headspaced correctly when it left the factory. Some Chinese worker wittled on it with a file to get it to fit. He didn't care if both lugs contacted or not. It just had to headspace. Now someone shoots it and the lug starts to collapse until the other one finally engages. Add to that the soft bolt in the first place, and it results in excessive headspace. That's how you got to where you are now.
Supposedly, Chinese barrel may sitll give you a good headspace reading somehow and not allow the bolt to support the case properly. This could result in a Ka Boom according to Fulton Armoury. I'm not entirely clear on this myself. I didn't bother to research it further as my plan was to replace all the parts with USGI to simply eliminate the whole mess.
The cost of barrel replacement isn't something to be taken lightly either. I mean that is a big chunk of change. It's your gun, if you feel fine about it, great. As you've figured out from the math, having Smith do it is more cost effective in the end than just doing it yourself if it's a one time deal.
A good idea may be to actually ask Clint at Fulton why exactly a Chinese barrel shouldn't be used. Just e-mail him or call him. He's supposed to be a stand-up guy and will yack guns forever. Find out why he doesn't like the barrels, but loves the receivers. If you were thinking of having Smith do the work, give them a call and see what they say. Sure, they're going to want to sell you some service, but both these folks have reputations as being very straight with people. That's why they command the prices they do.
It's not some secret rocket science to working on an M14. It's not even hard. There's just alot of little things that either add up to a quality product or junk. If you're serious about doing the work yourself, get the Knudsen manual on building the M14. That has bounds of information you need.
Ross