My initial project began with a James Madison Tactical 80% polymer lower, with most of the remaining parts from Delta Team Tactical. Specifically, the "LE" 6-position stock with (mistake #1) AR-15 7.25" tube, 3.25" buffer and 11.25" spring, a generic LPK, "Goblin" upper, recoil technology BCG, a 15" free float hand guard, 18" Bear Creek (BCA) parkerized barrel, and an adjustable gas block with (mistake #2) mid-length tube. I also invested in a bunch of different brand mags, 20-round steel ASC, AR-Stoner (basically the same thing), 20-round poly Pro Mag, and 25-round Pmags.
Milling out the lower was fairly easy. For reference, A few years back, I had milled out a 7.62x39 AR-15 Polymer 80 lower. That went together well for a first-time build. Not so much this time. At about the same time here, i also bought a couple of BCA side-charge AR-15 uppers, one in .223 Wylde and one in 6.5 Grendel. Both functioned great on a Polymer 80 lower and a Rise Armaments drop-in trigger.
The first problem was the bolt would not lock back on an empty mag. The second one was unreliable feeding. I could get it to hold manually, but as it turns out the problems here were entirely related to the wrong buffer parts. I didn't find this out until I had tried several mags and bolt catches.
Along the way, I became interested in the side-charging 308 uppers sold by Bear Creek. I waited (not long enough, the same upper was $40 less about 2 weeks later) for one I liked to go on a 10% off sale and bought it. This one has their 20" parkerized barrel, and is very similar to the other upper aside from side charging. I found this upper would also not lock back on an empty mag. I had reached out to both James Madison and Delta for some help. While both were helpful, neither found the root problem.
I also picked up an 80 Percent Arms Gen 3 jig and their aluminum lower. I managed to punch a hole in the floor of it and break off 2 of the 3 tangs on the end mill, but the lower came out OK otherwise.
Since I'm mechanically-oriented (I mod cars and bikes), I looked at the parts and marked my BCG in the buffer tube while it was all apart. I found the buffer and the spring were both too long. I had a heavy (5.x ounce) Armalite buffer that was 3.25" long, so I cut it down to 2.5" and dropped one of the weights out of it. It ended up around 4 ounces (less than ideal). Trying this as well, I found the BCG still would not come back quite far enough, so I cut down a spring from about 11.75" to about 9". Success! The bolt catch now worked as it should. I knew a cut-down spring and light buffer was not the permanent solution, though, so I did more reading and learned the LR-308/AR-10 uses a longer (7.75") buffer tube than the 7.25" AR-15 tube I had.
I did some test firing with the above combo and the guns ran well, I had a 3-4 o'clock ejection using steel case ammo.
I picked up a couple of 2.5" buffers, one 5.x ounces the other 3.x (don't recall exact numbers). See attached pic for reference. One has a "nub" on the end that prevents the upper from opening for servicing! The other has a high shoulder and won't work even with the cut down spring (it will likely work with the longer buffer tube).
I did some more reading, some at this site, and also at others. Here's what I learned to solve my problems:
1. The mid-length gas tube was slightly too short for my upper per a very helpful post by member 98Z5V. The tube should terminate halfway in the notch you see with the bolt open. Mine (Goblin upper) was about 1/4" too short. I found the actual Armalite AR-10 tube was the correct length (12.x), and bought it.
2. There IS a difference between AR-10 and AR-15 carbine buffer tubes! My tube, AR-15, was 7.25" long. The AR-10 tube is 7.75" long. Just like with the gas tube and buffer, a fraction of an inch makes a difference. I have ordered 2x Leapers # TLU002 tubes for my guns (not depicted).
So my plan at this point is to get another proper 5.x ounce 2.5" buffer and another of the Armalite springs, then use them with the Leapers tubes.