I got your parts yesterday and had a chance to work on them today. The magazine that had gotten the rounds stuck had totally missed our final sizing process – it was .015″ too wide – it could never work at all. We normally size the “cup” width within .002″ of spec. I put the magazine through our sizing process and ran the QC gages through it . . .
I looked at your barrel and the runout was way too much – next week we will be getting the new production barrels which are made on centers, and will use one of those as replacement.
I stripped the slide all the way down and rounded several edges that could catch on the shell casing, delaying it from leaving the ejection port. Then I re-blasted the slide with Zirconia. The casings should now “slide through”.
As far as the magazine with the popped out spring – I didn’t find anything out-of-spec on the spring or the magazine – I’m wondering if it had come out because there was a lone bullet in there tangling it up during a separation. What I did do with both magazines is close the upper magazine lips in about .015″ – this should be much better for retaining the spring. The top two coils of the spring actually comprise the follower. There are a lot of examples out there where wire-forms have replaced solid surfaces – shelving is one example that comes to mind.
Your slide assembly and magazines will be test-fired on one of our receivers (I’ll probably just use my current carry gun – a recent Platinum model) with standard pressure and +P ammunition to make certain the issues you had are no longer present.
While you may ask why we didn’t request the whole gun back, we have learned that most issues customers have had lie in the slide assembly, which is much cheaper to ship. The only times where we had to get the whole gun back was with pins walking out (we use set screws now) and sticky triggers. Our receivers, and all the parts in them, are consistent within a few thousandths of an inch from gun to gun, so testing a slide assembly on an interchangeable receiver is considered a valid test.
It is rare to see such service and I look forward to receiving everything back running a bunch of ammo through the gun.