[CDN_SAFN]

You're right about throwing the cases... I usually open up the gas sleeve whenever I am trying new ammo, and slowly start to close it off 2 settings past where it starts to cycle properly. The bolt doesn't feel like it's slamming into the back of the receiver, and it cycles reliably. (well, the 30-06 does)

I don't have any micrometers, but I do have pattern-maker's calipers. I can take a sizing from the 30-06 and see how it transfers over, but this would be on the outside of the piston itself. I don't have any reliable way to check the internal clearances myself. I do have access to hydraulics/pneumatics parts. I'm pretty sure I can get tefflon coil-wipers that would go on like piston rings the right size for the gas piston to try a few shots. They look like tiny sections of a slinky spring, I'd just have to find one with a suitable inside/outside diameter of the tefflon itself. They self-tension and gap seal, though at very low friction and wall pressure so it would work pretty well I think.

You may be onto something with the gas block... I'll try and see if I can't find any visual clues at first, then maybe a thin coat of plumbers paste on all the seams to show any blow-throughs after 1 shot. I never even considered that...

If it does prove to be the gas block, then it's really too bad that Numrich no longer has any new 8mm barrels. That would probably be the easiest route and give me an even better shooter in the end. Too bad there doesn't seem to be any more "one stop shopping" for parts. I'll take another close look over the weekend, but doubt I'll get any range time in for a few weeks. I will go over everything again with a good cleaning, and try to do a closer comparison with the 30-06.

Thanks for the gas block lead... makes good sense.

Dumb question maybe, but can pics be posted? If not, can links? I'd like to post pics of whatever turns out to be the deficiency and how it was determined in case someone else could benefit. And, if there was a solution that someone may be able to attempt themselves, or decide to take to a professional.

Oh, one last question... where can I find some more info/manuals etc. on the 49? I've already printed the parts diagram from Numrich, and there are fairly decent articles on it at surplusrifle.com I'm likely going to order their 2 CD's anyhow, since I have other C&R rifles and pistols that they have info on, but I've learned that you can always learn more if you keep looking. I can't own a FAL here in Canada, or gain a license to, but have a real respect for both the FAL (and variants) and the 49. I own 2 Garands and a Johnson and in my own opinion/experience with my own rifles, I prefer the 49 and feel it has some distinct advantages and overall superior build quality over both of the other rifles. If I could find any fault, it would be that the magazine is close to the point of balance, and it's depth (or length if you prefer) makes one handed carry less balanced. Aside from that, I don't find either the Garand or the Johnson as good a rifle overall. Then again, I've never had to use any of them in combat, so maybe my 2 cents worth is not at all relevant to the design of any of them.