Why is there a difference between commercial and mil-spec buffer tubes?

The commercial tube though slightly larger in OD will be weaker.;)

Those threads are cut into its wall thickness, and you get a notch effect at the last thread plus a thinner wall at that point. Ever break of an NPT fitting thats screwed into a heavy section?

It will always fail at the notch created by the last thread. If the NPT pipe fitting was built like a mil-spec thread, it would merely bend without fracturing at the thread induced notch.

The Mil-Spec tube has its threaded portion cut from a larger original OD and accompanying thicker wall. Then the thicker un-threaded sectioned is turned to a smaller OD than the threaded part. This eliminates the dreaded notch thus making it a stronger design.

As to our commercial AR's and how long they will last with the notch effect in place, I won't comment.
Kevin is right, the Mil-Spec is a superior strength design.
 
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