590A1 sticking hulls with Challenger Magnum buck

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Been running a 590A1 (20” barrel) and had a weird one at the range Friday. Recently installed a Vanguard M-LOK forend along with the OEM 590A1 heat shield, and swapped to an SGA-style stock. The Vanguard forend was extremely tight going on, had to mallet it into place onto the action tube. The nut that retains it isn’t is on and can’t be tightened any further but the notches aren’t lined up horizontally with the barrel one notch is slightly higher than the other, but it’s not stuck, just snug and won’t turn further and not cross threaded. No rubbing between the forend and heat shield that I can find, and the action cycles smooth through full travel.
For cleaning beforehand I ran a BoreSnake with CLP up front and dry at the back (didn’t fully dry it after), and separately used Lucas Extreme Duty grease and oil — pea-sized amounts spread thin on the action bars, the metal-on-metal tracks, and general sliding surfaces.
At the range: Challenger low-recoil target slugs cycled and extracted 100%, no issues. Switched to Challenger Magnum 00 buck and started getting FTEs after 1-2 rounds — fired hull physically stuck in the chamber, had to borrow a rod from the RO to punch it out. RO watched me try again with the same load and it ran fine that one time, so it’s not 100% consistent. Opened a second, fresh box (same lot) later and it did it again.
On a couple of the stuck hulls there was a small nick/mark on one side of the brass head, like the extractor was fighting to pull it free.
For reference, I’ve run this same Challenger Magnum buck (different box, same lot) through my 1301 with zero problems. I’ve also shot Federal buck through this same 590A1 in the past with no issues, before any of the furniture changes.
Haven’t cleaned it again yet to strip out the grease/oil — wanted to post first and see if anyone has run into this exact pattern before I go tearing back into it. Planning to do a proper chamber-brush-and-dry-patch clean and retest with Federal buck first before touching more Challenger.
Anyone dealt with a specific buckshot load sticking in a 590 chamber while everything else (slugs, other brands) runs fine? Trying to figure out if this is a “chamber doesn’t like this load” thing, residual lube making it worse, or something I should get looked at.
 
Some of the Challenger hulls are pretty soft plastic, while many of the premium hulls are stiffer and thus don’t allow the hull to conform to the chamber as easily under heat and pressure. Once these soft plastic hulls conform to any imperfection in a chamber, they become difficult to eject.

First thing I’d do is polish the chamber with a 12 gauge bronze brush, some 0000 wool wrapped around it, a little lubricant, and a power drill on slow speed. I’ve had success with this method. You might be surprised what you get out of the chamber and it’ll leave it with a mirror shine that’s slick. Clean it well afterwards as any bits of steel wool left down the barrel will rust.

There are videos and instructions on YouTube.
 
I have also had luck polishing. After I was done the guns even ran that crappy Winchester Universal garbage.
Mine too. It was that crap Winchester my shotgun was struggling ejecting. I shoot a lot of squirrels with it around the property (gods golf balls). Don’t feel bad for them tho, they’re totally a nuisance chewing through lots of stuff (wires, lattice work, my bbq cover 😤)

I was also surprised that I got out a lot of rust looking junk - I don't know if it was dried preservative or actual rust. The Mossberg shotguns seem to have this as a documented issue.
 
How many miles on this 590A1? Dulled extractor with weak spring?

Have you polished the chamber, if so, did you over polish it (enlarged it)?
 
How many miles on this 590A1? Dulled extractor with weak spring?

Have you polished the chamber, if so, did you over polish it (enlarged it)?
It’s basically brand new, bought it earlier this year probably less than 200 ish through it atp? I’ve cleaned it twice now (including before this range trip). I haven’t polished it or anything but would probably take it tacord if it comes to it.

I’m kind of worried I might have maybe bent the action bars slightly out of spec by forcing the forend on and that might be causing the bolt to be slightly out of alignment? I’m just thinking out loud tbh
 
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