If you load 5 or 6 rounds (look at both feed lips), you’ll see that the feed lips are holding the case along the full length. When you get to around 20 rounds in the magazine, you’ll start to see that the lips of the magazine are really only holding the case near the rim. The left-side feed lips are usually pretty good, but the right-side feed lips have all left the front end of the cases of the rounds without much support. There seemed to be a logical connection.
You need to be prepared to finish manufacturing the magazine tubes. In a somewhat rare fashion, I decided that this particular job was better to handle with some finesse, rather than brute force. Another Spike’s 5.45mm upper owner said he fixed the magazines with a hammer. I decided to make another magazine lip tool, and I bend the feedlips. . . carefully. At first, I was just bending the lips to hold the cases of the rounds better when loaded to capacity. This resulted in about a 50% success rate. Some of the newly tuned magazines ran fine. Some still jammed as if I hadn’t done anything. Some of the magazines would feed up until the 2nd to last round, and then jam.
The problem seems to be related to the angle that the bullets were presented. With the magazines that worked, the tips of the bullets were only a few millimeters above the front edge of the magazine. The ones that continued to jam, as if I hadn’t done anything, had the bullets sitting higher. The ones that didn’t jam until the 2nd to last round, I had bent the feed lips too far, and the tip of the bullet was almost even with the front edge of the magazine.
The modified magazines hold the 5.45mm ammo at the same angle as my D&H aluminum U.S.G.I.-type 5.56mm magazines. Yeah, I guess maybe I should have checked this earlier.
New strategy. Take one of the magazines that works, and fix the others to match it. This seems to be working well. I think maybe I got this figured out.