Time for an update: I'm an idiot, a total and complete utter moron. Seriously, everyone gets a turn to slap me upside the skull and stomp my balls, believe me I deserve it.
My only gas problem is with the quantity occupying space where brain cells should be. I shall explain.
I've been tinkering around since adding the LAW Tactical adapter to my rifle, and I noticed that with an empty mag in the rifle, the bolt will lock to the rear (behind the catch) if you withdraw the BCG with the adapter in the open position. While that's normal function for most of you all, since my rifle has been built, the bolt has never locked to the rear on empty. I have always attributed that to two particular factors:
1. I have used (1st Gen) PMAGS exclusively in this build, and they are reputed to be inconsistent in function with various large AR platforms.
2. Both custom BCGs used in the lifetime of this build feature chamfers at the front of the carrier that override the bolt catch.
Where the idiocy comes in, is how I've failed to realize the catch is supposed to hold on the face of the BOLT, not the carrier. So I began diagnosing why my carrier wasn't/isn't traveling far enough to the rear to function properly. The short answer is that my buffer is ~1/2" too long, explaining both my short-stroking/bcg overspeed issue, and the failure to lock back on empty. Doh!
This became apparent once I compared my buffer measurements with the data mrraley published quite a while ago. Brownells sent me an Armalite AR-15 buffer! It's 5.875" and should measure 5.188"! (Based on this post.)
So, while I will still manufacture my stainless heavy buffer, and add my SLR adjustable gas block to the system, I'm first going to modify the existing buffer to the correct length, and see if that corrects my function issues.