AR-15 Barrel Procedure: A Critical PSA from the Bench

While we’ll cover this in more detail on an upcoming episode of the Texas Predator Hunting Podcast, we wanted to share a quick but important PSA for anyone working with AR-15 barrels:

Always Clean Your AR-15 Barrel Before Installation

This is not just a suggestion—it’s a necessary step. We’ve seen more and more barrels arrive with burrs left behind from gas port drilling. These can lead to serious issues once the rifle is fired.

Start With a Brush

Before you install that barrel, take a few extra minutes and run a brush through the bore, paying particular attention to the gas port area.

Manufacturers are increasingly skipping proper deburring during production, and as gas port sizes grow (especially with ARCs and suppressed setups), those burrs can become a major problem.

We’ve had barrels sent in where the gas port was completely fouled with copper—caused by burrs scraping projectiles on their way through the bore. The end result: gas system failure.

What We Recommend

This is the same process we follow at Ally Munitions during our inspection and build procedures:

1. Brush the barrel, focusing on the gas port.

2. Flush with compressed air to remove any metal shavings.

3. Run patches until clean.

4. Borescope the barrel if possible, to confirm it's free of burrs and debris.

5. Then—and only then—install the barrel.

Why It Matters

• Over the last few years, we’ve found burrs in more than 95% of barrels inspected.

• These burrs can break free and clog:

  • The gas block

  • The gas tube

  • The bolt carrier key

  • Even the chamber in the BCG

We’ve diagnosed numerous gassing issues that traced back to metal debris from the barrel’s gas port—a completely avoidable problem.

Looking Ahead

We’re currently working on a way to de-chamfer gas ports in-house and will report on that as we refine the process. As manufacturers cut corners and port sizes grow, this is no longer just a good idea—it’s essential.

Take the time. Clean the barrel. Scope it if you can.
A few minutes of prep can save you hours of frustration and lost performance down the line.