Ran factory ammo. Works perfect. No FTF. However on a few last round it would go back to the 3/4 stop once empty
What's a 3/4 stop?
Are you saying it's catching on the carrier and not on the bolt face?
Since this is a build, what LPK did you use? Maybe it's not locking back because of a bad catch not the gas system. Does the bolt catch moove freely? Strong spring? When activated does it move up far enough to catch the bolt or is it just catching the lower edge?
Strange that it still short strokes occasionally. With the gas block adjuster wide open and a low mass carrier you should be overgassed.
Have you tried other magazines? Same ones that work well in your S&W?
Try swapping in the bolt carrier from your S&W and see if it helps or makes it worse. Also try the low mass carrier in the S&W and see how it shoots.
Have you tried sticking drill bits into the gas port yet (to measure the port size)? Is the port wide open into the bore with no crud in there? Same with the gas block, it there any way to see if there is an obstruction? Blow air backwards through it or remove the adjuster screw and inspect it and the port?
Just trying to see if we can narrow down what is causing the issues.
Have you read the AR lubrication sticky yet?
Improper lubrication can cause issues as well, too much and too little. People like to say an AR needs to run wet. This is false, it needs to be lubricated properly not just loaded up to where it's oozing out all over the place like I've seen some guys do.
Note to every member, the Magpul BAD lever is the worst thing they've ever made and has caused nothing but problems for many people. If you like what the BAD lever does but want something reliable look at the Phase5 EBR. It's a much better option.